Robotic surgical assemblies

ABSTRACT

A robotic surgical system includes a robotic arm, a carriage coupled to the robotic arm, a drive belt, and a motor supported by the carriage. The carriage rotatably supports an instrument rotation pulley and a motor axis pulley. The drive belt is coupled to the instrument rotation pulley and the motor axis pulley. The motor includes a coupling that is driven by the motor upon an actuation of the motor. The coupling is engaged with the motor axis pulley such that rotation of the motor axis pulley rotates the drive belt to rotate the instrument rotation pulley.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a U.S. National Stage Application filed under 35U.S.C. § 371(a) of International Patent Application Serial No.PCT/US2017/033899, filed May 23, 2017, which claims the benefit of andpriority to each of U.S. Provisional Application No. 62/341,714, filedMay 26, 2016; U.S. Provisional Application No. 62/341,701, filed May 26,2016; U.S. Provisional Application No. 62/341,720, filed May 26, 2016,U.S. Provisional Application No. 62/341,748; filed May 26, 2016, U.S.Provisional Application No. 62/341,761, filed May 26, 2016; U.S.Provisional Application No. 62/341,774, filed May 26, 2016; and U.S.Provisional Application No. 62/341,804, filed May 26, 2016, the entirecontents of each of which are incorporated by reference herein.

This application also claims the benefit of and priority to each of U.S.National Stage Application filed under 35 U.S.C. § 371(a) ofInternational Patent Application Serial No. PCT/US2017/033902, filed May23, 2017; U.S. National Stage Application filed under 35 U.S.C. § 371(a)of International Patent Application Serial No. PCT/US2017/033903, filedMay 23, 2017; U.S. National Stage Application filed under 35 U.S.C. §371(a) of International Patent Application Serial No. PCT/US2017/033905,filed May 23, 2017; U.S. National Stage Application filed under 35U.S.C. § 371(a) of International Patent Application Serial No.PCT/US2017/033926, filed May 23, 2017; U.S. National Stage Applicationfiled under 35 U.S.C. § 371(a) of International Patent ApplicationSerial No. PCT/US2017/033931, filed May 23, 2017; U.S. National StageApplication filed under 35 U.S.C. § 371(a) of International PatentApplication Serial No. PCT/US2017/033935, filed May 23, 2017, the entiredisclosures of which are incorporated by reference herein.

BACKGROUND

Robotic surgical systems have been used in minimally invasive medicalprocedures. Some robotic surgical systems include a console supporting asurgical robotic arm and a surgical instrument, having at least one endeffector (e.g., forceps or a grasping tool), mounted to the robotic arm.The robotic arm provides mechanical power to the surgical instrument forits operation and movement. Each robotic arm may include an instrumentdrive unit that is operatively connected to the surgical instrument.

Manually-operated surgical instruments often include a handle assemblyfor actuating the functions of the surgical instrument. However, whenusing a robotic surgical system, no handle assembly is typically presentto actuate the functions of the end effector. Accordingly, to use eachunique surgical instrument with a robotic surgical system, an instrumentdrive unit is used to interface with the selected surgical instrument todrive operations of the surgical instrument. In robotic surgicalsystems, a robot arm may be used to hold the surgical instrument. Insome robotic surgical systems, the entire length of the elongate shaftof the surgical instrument must pass through a holder or other featureof the robot arm, thereby making the removal or exchange of the surgicalinstrument cumbersome.

Accordingly, a need exists for a robotic surgical system that enablesmore efficient and expeditious removal or exchange of a surgicalinstrument.

A need further exists for a robotic surgical system in which the axis ofrotation of a surgical instrument takes place in a robotic arm of therobotic surgical assembly as compared to within the surgical instrumentitself. In this manner, the construction and assembly of the surgicalinstrument is simplified and more cost efficient.

Further, a need exists for a robotic surgical system having improved andincreased usability. For example, a need also exists for a roboticsurgical system that is manually controllable in emergency situations.

SUMMARY

In accordance with an aspect of the present disclosure, a roboticsurgical system is provided. The robotic surgical system includes arobotic arm, a carriage coupled to the robotic arm, a drive belt, and amotor supported by the carriage. The carriage rotatably supports aninstrument rotation pulley and a motor axis pulley. The drive belt iscoupled to the instrument rotation pulley and the motor axis pulley. Themotor is supported by the carriage and includes a coupling that isdriven by the motor upon an actuation of the motor. The coupling isengaged with the motor axis pulley such that rotation of the motor axispulley rotates the drive belt to rotate the instrument rotation pulley.

In some embodiments, the robotic surgical system may include a surgicalinstrument configured to couple to the carriage. The surgical instrumentmay operably couple to the instrument rotation pulley such that rotationof the instrument rotation pulley rotates the surgical instrument.

The robotic surgical system may comprise a sterile barrier housingincluding a drive transfer assembly configured to couple to the surgicalinstrument. The sterile barrier housing may include a cap. The cap maybe removable to expose an internal cavity defined within the sterilebarrier housing. The cavity may be configured to selectively receive amotor pack therein.

In certain embodiments, the robotic surgical system may further comprisea sterile barrier collar assembly configured to couple to the drivetransfer assembly. The sterile barrier collar assembly may be configuredto support the surgical instrument while the surgical instrument iscoupled to the drive transfer assembly. The drive transfer assembly andthe sterile barrier collar assembly may rotate together in response torotation of the instrument rotation pulley so that the surgicalinstrument rotates along a longitudinal axis thereof while coupled tothe sterile barrier collar assembly.

The robotic surgical system may further comprise a motor pack supportedin the sterile barrier housing. The motor pack may rotate with the drivetransfer assembly relative to the sterile barrier housing.

In some embodiments, the robotic surgical system may further include atension pulley operably coupled to the drive belt.

According to another aspect of the present disclosure, a roboticsurgical system includes a surgical instrument, an instrument driveunit, and a carriage supporting the instrument drive unit and thesurgical instrument while the surgical instrument is coupled to theinstrument drive unit. The surgical instrument defines a longitudinalaxis between proximal and distal ends thereof. The instrument drive unitmay be configured to transmit rotational forces to the surgicalinstrument while the surgical instrument is coupled to the instrumentdrive unit.

The carriage includes an instrument rotation pulley, a motor axispulley, a drive belt coupled to the instrument rotation pulley and themotor axis pulley, and a coupling. The coupling may be engaged with themotor axis pulley such that rotation of the coupling rotates the drivebelt around the instrument rotation pulley and the motor axis pulley torotate the surgical instrument about the longitudinal axis of thesurgical instrument.

In some embodiments, the robotic surgical system may include a roboticarm supporting a rail. The carriage may be movably mounted to the railof the robotic arm. The carriage may include a rear panel coupled to therail and a coupling flange extending from the rear panel. The couplingflange may rotatably support the instrument rotation pulley.

In certain embodiments, the instrument drive unit may include a sterilebarrier housing having a drive transfer assembly extending therefrom.The drive transfer assembly may be configured to couple to the surgicalinstrument. The sterile barrier housing may include a cap. The cap maybe removable to expose an internal cavity defined within the sterilebarrier housing. The cavity may be configured to selectively receive amotor pack therein.

The robotic surgical system may include a sterile barrier collarassembly configured to couple to the drive transfer assembly. Thesterile barrier collar assembly may be configured to support thesurgical instrument while the surgical instrument is coupled to thedrive transfer assembly. The drive transfer assembly and the sterilebarrier collar assembly may rotate together in response to rotation ofthe instrument rotation pulley so that the surgical instrument rotateswhile coupled to the sterile barrier collar.

In some embodiments, the robotic surgical system may include a motorpack supported in the sterile barrier housing. The motor pack may beconfigured to engage the drive transfer assembly so that the drivetransfer assembly provides a sterile interface between the motor packand the surgical instrument. The motor pack may rotate with the drivetransfer assembly relative to the sterile barrier housing.

In some embodiments, the carriage further includes a tension pulleyoperably coupled to the drive belt.

In accordance with yet another aspect of the present disclosure, therobotic surgical assembly includes a carriage, a shell mounted to thecarriage, a sterile barrier housing removably connectable to the shell,and a motor pack. The sterile barrier housing may define a cavitytherein and may have a drive transfer assembly extending distallytherefrom. The motor pack may be selectively receivable within thecavity of the sterile barrier housing and may be configured to interfacewith the drive transfer assembly of the sterile barrier housing whilereceived within the cavity of the sterile barrier housing to transmitrotational forces from the motor pack to the drive transfer assembly.The drive transfer assembly is configured to transmit rotational forcesto a surgical instrument coupled to the drive transfer assembly.

The robotic surgical assembly may include a lock ring rotatablysupported on the sterile barrier housing. The drive transfer assemblymay be rotatable relative to sterile barrier housing, and the lock ringmay support a tactile feedback ring that may be configured to couple tothe drive transfer assembly to provide tactile feedback as to an angularorientation of the drive transfer assembly.

In some embodiments, the sterile barrier housing may include a coverpivotally coupled thereto to selectively close the motor pack within thecavity.

In certain embodiments, the robotic surgical assembly may furtherinclude a sterile drape coupled to the shell. The sterile drape may bepositionable to establish a sterile barrier.

The robotic surgical assembly may further include a robotic arm having arail supported on the robotic arm. The carriage may be axially movablealong the rail. The carriage may include a coupling flange thatrotatably supports an instrument rotation pulley. The instrumentrotation pulley may define an opening therethrough. The opening maydefine a key-way for non-rotational receipt of the drive transferassembly.

In some embodiments, a sterile barrier collar assembly may be configuredto couple to the drive transfer assembly. The sterile barrier collarassembly may be configured to support the surgical instrument while thesurgical instrument is coupled to the drive transfer assembly. The drivetransfer assembly and the sterile barrier collar assembly may rotatetogether in response to rotation of the instrument rotation pulley sothat the surgical instrument rotates along a longitudinal axis thereofwhile coupled to the sterile barrier collar assembly.

In certain embodiments, the motor pack may rotate with the drivetransfer assembly relative to the sterile barrier housing.

According to one aspect of the present disclosure, a robotic surgicalsystem includes a robotic arm, a surgical instrument, and a roboticsurgical assembly coupled to the robotic arm and configured to supportthe surgical instrument.

The robotic surgical assembly includes a carriage, a shell mounted tothe carriage, a sterile barrier housing connectable to the shell, and amotor pack supported by the sterile barrier housing. The sterile barrierhousing may have a drive transfer assembly extending distally therefrom.The motor pack may be configured to interface with the drive transferassembly of the sterile barrier housing to transmit rotational forcesfrom the motor pack to the drive transfer assembly. The drive transferassembly may be configured to transmit rotational forces to the surgicalinstrument.

In certain embodiments, a lock ring may be rotatably supported on thesterile barrier housing. The drive transfer assembly may be rotatablerelative to sterile barrier housing, and the lock ring may supports atactile feedback ring that is configured to couple to the drive transferassembly to provide tactile feedback as to an angular orientation of thedrive transfer assembly.

In some embodiments, the sterile barrier housing may include a coverpivotally coupled thereto to selectively close the motor pack within thecavity.

The robotic surgical system may include a sterile drape coupled to theshell. The sterile drape may be positionable to establish a sterilebarrier.

In certain embodiments, the robotic arm may include a rail and thecarriage may be axially movable along the rail. The carriage may includea coupling flange that rotatably supports an instrument rotation pulleythat defines an opening therethrough. The opening may define a key-wayfor non-rotational receipt of the drive transfer assembly.

The robotic surgical system may include a sterile barrier collarassembly configured to couple to the drive transfer assembly. Thesterile barrier collar assembly may be configured to support thesurgical instrument while the surgical instrument is coupled to thedrive transfer assembly. The drive transfer assembly and the sterilebarrier collar assembly may rotate together in response to rotation ofthe instrument rotation pulley so that the surgical instrument rotatesalong a longitudinal axis thereof while coupled to the sterile barriercollar assembly. The motor pack may rotate with the drive transferassembly relative to the sterile barrier housing.

In accordance with still another aspect of the present disclosure, asterile interface module for coupling an electromechanical roboticsurgical instrument to a robotic surgical assembly is provided. Thesurgical instruments including an end effector and may be configured tobe actuated by the robotic surgical assembly.

The sterile interface module includes a body member configured toselectively couple the surgical instrument to the robotic surgicalassembly. The body member may be formed of a dielectric material. Thesterile interface module may include a drive assembly supported withinthe body member and may be configured to transmit rotational forces fromthe robotic surgical assembly to the surgical instrument to actuate thesurgical instrument to enable the surgical instrument to perform afunction.

In some embodiments, the body member may support an electrical connectorthat electrically communicates information between the robotic surgicalassembly and the surgical instrument. The body member may support anelectrosurgical connecting member that is configured to transmitelectrosurgical energy from the robotic surgical assembly to thesurgical instrument. The electrosurgical connecting member may beelectrically isolated from the electrical connector.

In certain embodiments, the drive assembly may include a drive couplerand a transfer shaft extending from the drive coupler. The drive couplermay be engagable with the robotic surgical assembly and the transfershaft may be engagable with the surgical instrument. The drive couplerand the transfer assembly may be robotically movable to operate the endeffector of the surgical instrument.

The sterile interface module may include a rotatable collar supported onthe body member. The sterile interface module may include a ring couplersecured to the rotatable collar, a drive coupler secured to the transfershaft of the drive assembly, and an idler coupler supported between thedrive coupler and the ring coupler. The ring coupler may be selectivelyengagable with the idler coupler as the rotatable collar rotates betweena first position and a second position.

In some embodiments, the sterile interface module may further include afloating plate coupled to the body member. The floating plate may bemovable relative to the body member to facilitate selective connectionof the surgical instrument to the body member. The floating plate may bespring biased.

In one aspect of the present disclosure, a robotic surgical systemincludes an electromechanical robotic surgical instrument, a roboticsurgical assembly, and a sterile interface module. The sterile interfacemodule has a body member formed of a dielectric material. The bodymember may be configured to selectively couple the surgical instrumentto the robotic surgical assembly to maintain sterility between therobotic surgical assembly and the surgical instrument. The body membermay support a drive assembly configured to transmit rotational forcesfrom the robotic surgical assembly to the surgical instrument to actuatethe surgical instrument.

The body member of the sterile interface module may support anelectrical connector that electrically communicates information betweenthe robotic surgical assembly and the surgical instrument while the bodymember is coupled to the robotic surgical assembly and the surgicalinstrument. The body member of the sterile interface module may supportan electrosurgical connecting member that is configured to transmitelectrosurgical energy from the robotic surgical assembly to thesurgical instrument. The electrosurgical connecting member may beelectrically isolated from the electrical connector.

In certain embodiments, the surgical instrument may include an endeffector. The drive assembly of the sterile interface module may includea drive coupler and a transfer shaft extending from the drive coupler.The drive coupler may be engagable with the robotic surgical assemblyand the transfer shaft may be engagable with the surgical instrument.The drive coupler and the transfer assembly may be robotically movableto operate the end effector of the surgical instrument.

In some embodiments, the sterile interface module may include arotatable collar supported on the body member of the sterile interfacemodule. The sterile interface module may include a ring coupler securedto the rotatable collar, a drive coupler secured to the transfer shaftof the drive assembly, and an idler coupler supported between the drivecoupler and the ring coupler. The ring coupler may be selectivelyengagable with the idler coupler as the rotatable collar rotates betweena first position and a second position. The ring coupler may rotatebetween the first and second positions to selectively disengage thedrive coupler from the robotic surgical assembly. Rotation of therotatable collar may result axial movement of the rotatable collar andselective engagement between the idler coupler and the rotatable collar.

In certain embodiments, the sterile interface module may include afloating plate coupled to the body member of the sterile interfacemodule. The floating plate may be movable relative to the body member ofthe sterile interface module to facilitate selective connection of thesurgical instrument to the body member of the sterile interface module.The floating plate of the sterile interface module may be spring biased.

According to still another aspect of the present disclosure, a surgicalinstrument for coupling to a robotic surgical assembly configured totransfer rotational forces to the surgical instrument is provided. Thesurgical instrument includes an elongated shaft, an end effector coupledto a distal end of the elongated shaft, and a drive assembly operativelycoupled to the end effector. The drive assembly includes one or morecables connected to the end effector, wherein movement of the one ormore cables actuates a movement of the end effector. The one or morecables may be coated with parylene.

In some embodiments, the one or more cables may be movable in responseto rotational forces transmitted from the robotic surgical assembly.

In certain embodiments, the drive assembly may include a drive screwsupporting a drive nut. The drive nut may be axially movable along thedrive screw as the drive screw rotates to move the one or more cables.

The surgical instrument may further include a second drive assemblyoperatively coupled to the end effector. The second drive assembly mayinclude a second drive screw supporting a second drive nut that isaxially movable along the second drive screw as the second drive screwrotates. The first and second drive nuts may be configured to move inaxially opposite directions as the first and second drive screws rotate.

In some embodiments, the drive assembly includes a biasing member thatmaintains the one or more cables in tension.

In certain embodiments, the surgical instrument includes a housingsupported on a proximal end of the elongated shaft. The housing may beconfigured to couple to the robotic surgical assembly. The housing mayinclude a side surface supporting a ramped camming surface. The rampedcamming surface may be configured to enable the housing to betransversely coupled to the robotic surgical assembly. The housing maysupport one or more electrical connectors configured to electricallycouple to the robotic surgical assembly so that the surgical instrumentcan electrically communicate with the robotic surgical assembly.

In some embodiments, the one or more cables may be formed of tungsten.

According to one aspect of the present disclosure, a robotic surgicalinstrument includes a housing configured to couple to a robotic surgicalassembly, an elongated shaft extending distally from the housing, an endeffector extending distally from the elongated shaft, and a driveassembly supported in the housing. The drive assembly includes a cableconnected to the end effector. The cable is movable to actuate the endeffector. The cable may be coated with an autoclavable material.

The cable may be movable in response to rotational forces transmittedfrom the robotic surgical assembly while the housing is coupled to therobotic surgical assembly.

In some embodiments, the drive assembly includes a drive screwsupporting a drive nut. The drive nut may be axially movable along thedrive screw as the drive screw rotates to move the cable. The roboticsurgical instrument may include a second drive assembly operativelycoupled to the end effector. The second drive assembly may include asecond drive screw supporting a second drive nut that is axially movablealong the second drive screw as the second drive screw rotates. Thefirst and second drive nuts may be configured to move in axiallyopposite directions as the first and second drive screws rotate.

In certain embodiments, the drive assembly includes a biasing memberthat maintains the cable in tension.

In some embodiments, the autoclavable material may include parylene. Thecable may be formed of tungsten.

In certain embodiments, the housing includes a side surface supporting aramped camming surface. The ramped camming surface may be configured toenable the housing to be transversely coupled to the robotic surgicalassembly. The housing may support one or more electrical connectorsconfigured to electrically couple to the robotic surgical assembly sothat the surgical instrument can electrically communicate with therobotic surgical assembly.

According to another aspect of the present disclosure, the roboticsurgical system includes a surgical instrument and a robotic surgicalassembly. The robotic surgical assembly defines an instrument openingand includes a floating plate and a drive assembly. The floating platemay be movable between an extended position and a compressed position.The surgical instrument may be laterally receivable in the instrumentopening of the robotic surgical assembly while the floating plate isdisposed in the compressed position. The floating plate may be movableto the extended position to couple the surgical instrument to therobotic surgical assembly while the surgical instrument is received inthe instrument opening of the robotic surgical assembly.

In some embodiments, the floating plate includes one or more tabsextending therefrom. The one or more tabs may be configured to engagethe surgical instrument to move the floating plate from the extendedposition to the compressed position.

In certain embodiments, the drive assembly may include one or morecouplers extending into the instrument opening while the floating plateis disposed in the extended position. The floating plate may move theone or more couplers out of the instrument opening as the floating platemoves from the extended position to the compressed position. Thesurgical instrument may include one or more couplers that complement theone or more couplers of the robotic surgical assembly. The one or morecouplers of the robotic surgical assembly may be configured to engagethe one or more couplers of the surgical instrument while the floatingplate is in the extended position and the surgical instrument is coupledto the robotic surgical assembly.

In some embodiments, the floating plate may be spring biased toward theextended position.

In certain embodiments, the robotic surgical assembly may include asemi-annular coupling cuff that defines the instrument opening. Thesemi-annular coupling cuff may include a U-shaped body. The couplingcuff may include a ramped surface formed on an inner surface of thecoupling cuff. The ramped surface may be configured to engage acomplementary surface formed on an outer surface of the surgicalinstrument so that the ramped surface of the coupling cuff supports thesurgical instrument in the instrument opening.

In some embodiments, the surgical instrument may include a housing andone or more paddles pivotally connected to the housing. The one or morepaddles may be engagable with the floating plate to move the floatingplate to the compressed position so that the surgical instrument canslide laterally through the instrument opening.

According to still another aspect of the present disclosure, a roboticsurgical assembly for selective engagement to a surgical instrument isprovided. The robotic surgical assembly includes a drive assemblyconfigured to transmit rotational forces to the surgical instrument, asemi-annular coupling cuff defining an instrument opening, and floatingplate. The floating plate may be movable between an extended positionand a compressed position. The coupling cuff may be configured toreceive the surgical instrument laterally through the instrument openingwhile the floating plate is in the compressed position. The floatingplate may be movable from the compressed position to the extendedposition to couple the drive assembly to the surgical instrument.

The floating plate may include one or more tabs extending therefrom. Theone or more tabs may be configured to engage the surgical instrument tomove the floating plate from the extended position to the compressedposition.

In some embodiments, the drive assembly may include one or more couplersextending into the instrument opening while the floating plate isdisposed in the extended position. The floating plate may move the oneor more couplers out of the instrument opening as the floating platemoves from the extended position to the compressed position. The one ormore couplers may be configured to engage the surgical instrument whilethe floating plate is in the extended position. The floating plate maybe spring biased toward the extended position.

In some embodiments, the coupling cuff may include a U-shaped body. Thecoupling cuff may include a ramped surface formed on an inner surface ofthe coupling cuff. The ramped surface may be configured to engage acomplementary surface formed on an outer surface of the surgicalinstrument so that the ramped surface of the coupling cuff supports thesurgical instrument in the instrument opening.

In certain embodiments, the drive assembly may be coupled to arobotically controlled motor assembly that actuates the drive assembly.

According to one aspect of the present disclosure, a sterile interfacemodule for coupling a surgical instrument to a robotic surgical assemblyis provided. The surgical instrument includes an end effector.

The sterile interface module includes a body member configured toselectively couple the surgical instrument to the robotic surgicalassembly. The sterile interface module further includes a first drivetransfer assembly supported by the body member. The first drive transferassembly includes a drive coupler and a transfer shaft extending fromthe drive coupler. The drive coupler may be engagable with the roboticsurgical assembly and the transfer shaft may be engagable with thesurgical instrument. The drive coupler and the transfer assembly may berobotically movable to operate the end effector of the surgicalinstrument.

A rotatable collar is supported on the body member and is operablyassociated with the first drive transfer assembly. The rotatable collarmay be manually movable relative to the body member to manually operatethe end effector of the surgical instrument. The rotatable collar maymove axially relative to the body member as the rotatable collar rotatesaround the body member.

The sterile interface module may further include a ring coupler securedto the rotatable collar. A drive coupler may be secured to the transfershaft of the first drive transfer assembly, and an idler coupler may besupported between the drive coupler and the ring coupler. The ringcoupler may be engaged with the idler coupler while the rotatable collaris in a first position and spaced from the idler coupler while therotatable collar is in a second position. The ring coupler may rotatethe idler coupler as the rotatable collar rotates around the bodymember. Rotation of the idler coupler may rotate the drive coupler torotate the transfer shaft.

In some embodiments, a second drive transfer assembly is configured tooperate the end effector of the surgical instrument in conjunction withthe first drive transfer assembly. The first drive transfer assembly maybe rotatable independent of the second drive transfer assembly as therotatable collar moves relative to the body member. The second drivetransfer assembly may be configured to remain stationary as therotatable collar rotates relative to the body member.

In certain embodiments, a floating plate may be coupled to the bodymember and a spring may be positioned between the drive coupler and thetransfer shaft. The floating plate may be movable with the transfershaft relative to the body member in a proximal direction to facilitateselective removal of the surgical instrument from the body member. Thespring may be configured to bias the floating plate in a distaldirection.

According to another aspect of the present disclosure, a roboticsurgical system includes a surgical instrument including an endeffector, a robotic surgical assembly, and a sterile interface modulepositionable between the robotic surgical assembly and the surgicalinstrument to couple the surgical instrument to the robotic surgicalassembly.

According to yet another aspect of the present disclosure, a method formanually operating an end effector of a surgical instrument coupled to arobotic surgical assembly is provided. The method includes rotating arotatable collar of a sterile interface module to axially move a ringcoupler relative to an idler coupler, selectively engaging the ringcoupler with the idler coupler, rotating the idler coupler with the ringcoupler to manually rotate a first drive transfer assembly while thering coupler is engaged with the idler coupler; and manipulating the endeffector of the surgical instrument in response to the manual rotationof the first drive transfer assembly.

The method may include axially spacing the ring coupler from the idlercoupler to disengage the ring coupler from the idler coupler. The methodmay include manually rotating the first drive transfer assemblyindependent of a second drive transfer assembly.

In accordance with an aspect of the present disclosure, a surgicalinstrument holder is provided. The surgical instrument holder includes acarriage, a housing, and a drive assembly. The carriage is configuredfor engagement to a surgical robotic arm and for supporting aninstrument drive unit. The carriage includes a motor. The housingextends from the carriage and defines a channel. The drive assemblyincludes a pulley, a belt, and an annular member. The pulley isrotatably disposed within the housing and in operable engagement withthe motor such that actuation of the motor rotates the pulley. The beltis rotatably disposed within the housing and in operable engagement withthe pulley such that rotation of the pulley effects rotation of thebelt. The annular member is disposed within the channel of the housingand configured for non-rotatable receipt of an instrument drive unit.The annular member is in operable engagement with the belt such thatrotation of the belt effects rotation of the annular member.

In some embodiments, the belt may be a closed loop and include teethextending from an inner surface of the belt. The annular member may haveteeth extending from an outer surface thereof and in operable engagementwith the teeth of the belt. The annular member may include a ring and anannular base plate disposed within the ring. The ring may have the teethof the annular member extending therefrom. The annular base plate maydefine one or more holes. The ring and the annular base plate maycooperatively define a cavity configured to receive an instrument driveunit.

It is contemplated that the carriage may further include a rotatabledrive shaft extending from the motor, and a shaft coupling non-rotatablyconnected to the drive shaft. The drive assembly may further include adriven shaft having a proximal end non-rotatably connected to the shaftcoupling, and a distal end non-rotatably connected to the pulley suchthat rotation of the drive shaft of the carriage effects rotation of theshaft coupling and in turn rotation of the pulley of the drive assembly.Each of the motor of the carriage, the drive shaft of the carriage, andthe driven shaft of the drive assembly may define a longitudinal axis inline with one another.

It is envisioned that the carriage may further include a printed circuitboard in electrical communication with the motor to control an operationof the motor.

In some aspects of the present disclosure, the belt may be pliable andconfigured to travel along an oblong semicircular shape defined by thehousing.

In some embodiments, the housing may include a sidewall defining anenclosure therein, and a base disposed within the enclosure andconnected to the sidewall. The base may define the channel of thehousing and an arcuate bottom ledge. The housing may further include anarcuate wall extending upwardly from the base. The drive assembly mayfurther include a first bearing and a second bearing. The first bearingmay be disposed in the housing and in engagement with the annularmember. The second bearing may be disposed on the arcuate bottom ledgeof the housing and in engagement with the annular member. The first andsecond bearings facilitate rotation of the annular member relative tothe housing.

It is contemplated that the drive assembly may further include a secondpulley rotatably disposed within the housing. The second pulley is inoperable engagement with the belt. The pulleys of the drive assembly arespaced from one another. The belt wraps around the pulleys of the driveassembly and around the annular member.

In another aspect of the present disclosure, a surgical assembly for usewith a surgical robotic arm is provided. The surgical assembly includesan instrument drive unit, and a surgical instrument holder. Theinstrument drive unit includes a housing and a motor assembly rotatablydisposed within the housing. The surgical instrument holder includes acarriage, a housing extending from the carriage, and a drive assembly.The carriage has a first side configured for movable engagement to asurgical robotic arm, and a second side configured for non-rotatablysupporting the housing of the instrument drive unit. The carriageincludes a motor. The housing of the instrument drive unit extends fromthe carriage and defines a channel. The drive assembly includes apulley, a belt, and an annular member. The pulley is rotatably disposedwithin the housing of the surgical instrument holder and in operableengagement with the motor of the carriage such that actuation of themotor of the carriage rotates the pulley of the drive assembly. The beltis rotatably disposed within the housing and in operable engagement withthe pulley such that rotation of the pulley effects rotation of thebelt. The annular member is disposed within the channel of the housingand configured for non-rotatable receipt of the motor assembly of theinstrument drive unit. The annular member is in operable engagement withthe belt such that rotation of the belt causes the annular member torotate resulting in rotation of the motor assembly of the instrumentdrive unit relative to the housing of the instrument drive unit.

In some embodiments, the annular member may include a ring and anannular base plate disposed within the ring. The ring may have the teethof the annular member extending therefrom. The annular base plate maydefine one or more holes that receive drive shafts of the motor assemblytherethrough. The ring and the annular base plate may cooperativelydefine a cavity configured to receive the motor assembly of theinstrument drive unit.

It is contemplated that the surgical assembly may further include asurgical instrument configured for non-rotatable connection with themotor assembly of the instrument drive unit. Rotation of the motorassembly of the instrument drive unit via the drive assembly of thesurgical instrument holder effects rotation of the surgical instrument.

Other aspects, features, and advantages will be apparent from thedescription, the drawings, and the claims that follow.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the present disclosure are described herein withreference to the accompanying drawings, wherein:

FIG. 1 is a schematic illustration of a robotic surgical systemincluding a robotic surgical assembly in accordance with the presentdisclosure;

FIG. 2 is a perspective view, with parts separated, of the roboticsurgical assembly and the electromechanical surgical instrument, inaccordance with an embodiment of the present disclosure;

FIG. 3 is a perspective view of a carriage of the robotic surgicalassembly, shown supported on a rail slide of the robotic surgicalsystem;

FIG. 4 is a perspective view of the carriage and rail of FIG. 3,illustrating a sterile shell and bag of the robotic surgical systembeing coupled and connected to the carriage and rail;

FIG. 5 is a side, elevational view of the carriage and rail of FIGS. 3and 4, illustrating the sterile shell and bag of the robotic surgicalsystem coupled and connected to the carriage and rail;

FIG. 6 is a side, elevational view of the carriage and rail of FIG. 5,illustrating a coupling or connection of a sterile barrier collarassembly according to an embodiment of the present disclosure, to thecarriage and rail;

FIG. 7 is a longitudinal, cross-sectional view of a motor pack of therobotic surgical assembly illustrated in FIG. 2, as taken through 7-7 ofFIG. 2;

FIG. 8 is a perspective view of canister motors and respective motorcouplers of the motor pack of FIG. 7;

FIG. 9 is a transverse cross-sectional view of components of the motorpack, a drive transfer assembly, and a lock ring of the robotic surgicalassembly of the present disclosure;

FIG. 10 is a top, plan view of the sterile barrier collar assembly ofFIG. 9;

FIG. 11 is a perspective view illustrating a drive coupler of thesterile barrier collar assembly connected to a respective motor coupler;

FIG. 12 is a perspective view of a tactile ring of the sterile barriercollar assembly;

FIG. 13 is a perspective view, with parts separated, of theelectromechanical surgical instrument, and a floating plate and acoupling cuff of the sterile barrier collar assembly of FIG. 9;

FIG. 14 is a perspective view of a drive assembly of theelectromechanical surgical instrument;

FIG. 15 is a cross-sectional view, as taken through 15-15 of FIG. 13;

FIG. 16 is a cross-sectional view, as taken through 16-16 of FIG. 15;

FIG. 17 is an enlarged, longitudinal, cross-sectional view of theelectromechanical surgical instrument coupled to the carrier via thesterile barrier collar assembly;

FIG. 18 is a further enlarged view of the illustration of FIG. 17, withthe electromechanical surgical instrument removed therefrom;

FIG. 19 is yet another enlarged view of the illustration of FIG. 17,with the electromechanical surgical instrument coupled to the roboticsurgical assembly and with drive transfer shafts of the robotic surgicalassembly separated from proximal couplers of the electromechanicalsurgical instrument;

FIG. 20 is still another enlarged view of the illustration of FIG. 17,with the electromechanical surgical instrument coupled to the roboticsurgical assembly and with the drive transfer shafts of the roboticsurgical assembly coupled to the proximal couplers of theelectromechanical surgical instrument;

FIG. 21A is a longitudinal, cross-sectional view of theelectromechanical surgical instrument coupled to the robotic surgicalassembly, as taken through a plane extending across release levers orpaddles of the electromechanical surgical instrument, and illustratingthe electromechanical surgical instrument coupled to the carrier via thesterile barrier collar assembly;

FIGS. 21B-21D are progressive views illustrating the electromechanicalsurgical instrument being coupled to the robotic surgical assembly;

FIG. 22 is a front, perspective view of a robotic surgical assembly,according to another embodiment of the present disclosure, shownsupported on a slide rail of the robotic surgical system and coupled toan electromechanical surgical instrument;

FIG. 23 is a rear, perspective view of the robotic surgical assembly andelectromechanical surgical instrument of FIG. 22;

FIG. 24 is a bottom, perspective view of the electromechanical surgicalinstrument connected to the robotic surgical assembly of FIG. 22, withportions thereof shown in phantom;

FIG. 25 is a bottom, perspective view of the robotic surgical assemblyof FIG. 22;

FIG. 26 is a cross-sectional view as taken through 26-26 of FIG. 24;

FIG. 27 is a perspective view of a pulley of the robotic surgicalassembly of FIG. 22;

FIG. 28 is a rear, bottom perspective view of a sterile barrier of therobotic surgical assembly of FIG. 22;

FIG. 29 is a front, top perspective view of the sterile barrier of therobotic surgical assembly of FIG. 22;

FIG. 30 is a front, perspective view of the electromechanical surgicalinstrument shown connected to a sterile barrier collar assembly of therobotic surgical assembly of FIG. 22;

FIG. 31 is a rear, perspective view of the electromechanical surgicalinstrument shown connected to the sterile barrier collar assembly of therobotic surgical assembly of FIG. 22;

FIG. 32 is a longitudinal, cross-sectional view of the robotic surgicalassembly and the electromechanical surgical instrument of FIG. 22, shownconnected to the slide rail;

FIG. 33 is an enlarged view of the indicated area of detail of FIG. 32;

FIG. 34 is a cross-sectional view of the robotic surgical assembly andthe electromechanical surgical instrument, as taken through 34-34 ofFIG. 32;

FIG. 35 is an enlarged view of the indicated area of detail of FIG. 34;

FIG. 36 is a side, elevational view, with parts separated, of anotherembodiment of a robotic surgical assembly and embodiments of variouselectromechanical surgical instruments for use with the robotic surgicalassembly of FIG. 2 or FIG. 36;

FIG. 37 is a top view of one embodiment of the various electromechanicalsurgical instruments shown in FIG. 36;

FIG. 38 is an enlarged, partial, cross-sectional view of a portion ofthe robotic surgical assembly of FIG. 1;

FIG. 39 is an enlarged, side, cross-sectional view of the roboticsurgical assembly of FIG. 1 with a sterile interface module thereofshown in a first position;

FIG. 40 is an enlarged, side, cross-sectional view of a portion of therobotic surgical assembly of FIG. 1 with the sterile interface modulethereof shown in a second position;

FIG. 41 is an enlarged, front view of a portion of the robotic surgicalassembly of FIG. 1 with the sterile interface module thereof shown in afirst position;

FIG. 42 is an enlarged, front view of the portion of the roboticsurgical assembly shown in FIG. 41 with the sterile interface modulethereof shown in a second position;

FIG. 43 is a perspective, cross-sectional view of the portion of therobotic surgical assembly shown in FIG. 41 with the sterile interfacemodule thereof shown in the first position;

FIG. 44 is a perspective, cross-sectional view of the portion of therobotic surgical assembly shown in FIG. 41 with the sterile interfacemodule thereof shown in the second position;

FIG. 45 is an enlarged, top, cross-sectional view of the sterileinterface module in the first position;

FIG. 46 is an enlarged, perspective view of a drive transfer assembly ofthe sterile interface module and a motor coupler of a motor assembly ofthe robotic surgical assembly of FIG. 1, the drive coupler shown in afirst state;

FIG. 47 is a perspective view of the drive transfer assembly and themotor coupler of FIG. 46 with the drive transfer assembly shown in asecond state;

FIG. 48 is a side, elevational view, with parts separated, of yetanother embodiment of a robotic surgical assembly according to thepresent disclosure;

FIG. 49 is a perspective view of a sterile interface module of therobotic surgical assembly of FIG. 48, illustrating a safety clip inposition;

FIG. 50 is a perspective view, with parts separated, of the sterileinterface module of FIG. 49;

FIG. 51 is a cross-sectional view as taken through 51-51 of FIG. 49;

FIG. 52 is a cross-sectional view as taken through 52-52 of FIG. 49;

FIG. 53 is a cross-sectional view as taken through 53-53 of FIG. 49;

FIG. 54 is a side elevational view of the sterile module interface ofFIGS. 48-53;

FIG. 55 is a cross-sectional, elevational view of the sterile moduleinterface of FIGS. 48-54, as taken through 55-55 of FIG. 49,illustrating the sterile module interface in a first condition;

FIG. 56 is a cross-sectional, elevational view of the sterile moduleinterface of FIG. 55, illustrating the sterile module interface in asecond condition;

FIG. 57 is a longitudinal, cross-sectional view of the robotic surgicalassembly of FIG. 48 including a surgical instrument connected thereto;

FIG. 58 is another longitudinal, cross-sectional view of the roboticsurgical assembly of FIG. 48 including a surgical instrument connectedthereto;

FIG. 59 is a perspective view of another embodiment of the surgicalassembly of FIG. 1 including a surgical instrument holder, an instrumentdrive unit, and a surgical instrument;

FIG. 60A is a perspective view, with parts separated, of the surgicalinstrument holder of FIG. 59;

FIG. 60B is a perspective view, with parts assembled, of the surgicalinstrument holder of FIG. 59;

FIG. 61 is a cross-sectional view, taken alone lines 61-61 in FIG. 60B,of the surgical instrument holder;

FIG. 62 is a perspective view, with parts separated, of a drive assemblyand a housing of the surgical instrument holder of FIG. 60B;

FIG. 63 is an enlarged view of the housing of the surgical instrumentholder of FIG. 62;

FIG. 64A is a cross-sectional view, taken along lines 64A-64A of FIG.63, of the housing of the surgical instrument holder;

FIG. 64B is the cross-sectional view of the housing as shown in FIG. 64Awith the addition of an annular member and a pulley of the driveassembly disposed therein;

FIG. 65A is a top view of the housing of FIG. 63;

FIG. 65B is a top view of the housing of FIG. 63 with the addition of abelt and a pulley of the drive assembly disposed therein;

FIG. 66A is a top view of the housing of the surgical instrument holderof FIG. 65B with the addition of a tensioning assembly;

FIG. 66B is a perspective view of the indicated area of detail shown inFIG. 66A;

FIG. 67 is a cross-sectional view, taken along lines 67-67 of FIG. 59,of the surgical assembly, illustrating the instrument drive unitdisposed in the surgical instrument holder; and

FIG. 68 is another cross-sectional view, taken along lines 68-68 of FIG.59, of the surgical assembly, illustrating the instrument drive unitdisposed in the surgical instrument holder.

DETAILED DESCRIPTION

Embodiments of the presently disclosed surgical assembly including aninstrument drive unit for driving the operation of an electromechanicalsurgical instrument and methods thereof are described in detail withreference to the drawings, in which like reference numerals designateidentical or corresponding elements in each of the several views. Asused herein, the term “distal” refers to that portion of the roboticsurgical system, surgical assembly, or component thereof, that is closerto a patient, while the term “proximal” refers to that portion of therobotic surgical system, surgical assembly, or component thereof, thatis further from the patient. As used herein, the terms parallel andperpendicular are understood to include relative configurations that aresubstantially parallel and substantially perpendicular up to about + or−10 degrees from true parallel and true perpendicular.

As used herein, the term “clinician” refers to a doctor, nurse, or othercare provider and may include support personnel. In the followingdescription, well-known functions or construction are not described indetail to avoid obscuring the present disclosure in unnecessary detail.

As will be described in detail below, provided is a surgical assemblyconfigured to be attached to a surgical robotic arm. The surgicalassembly includes an instrument drive unit having, for example, but notlimited to, a motor configured to rotate an electromechanical instrumentabout a longitudinal axis thereof. In some embodiments, the motor may bea hollow core motor. Additionally, provided is a feedback assemblyconfigured to determine and regulate the degree of rotation of theelectromechanical instrument about its longitudinal axis. The rotationof the electromechanical instrument may be achieved with a hollow coremotor, a canister motor (brushless or brushed), via a transmission(gear, belt and/or cable); via pneumatics, and/or via hydraulics. Theaxis of rotation of the electromechanical instrument may be integral tothe instrument drive unit or to the robotic arm.

Referring initially to FIG. 1, a surgical system, such as, for example,a robotic surgical system 1, generally includes one or more surgicalrobotic arms 2, 3, a control device 4, and an operating console 5coupled with control device 4. Any of the surgical robotic arms 2, 3 mayhave a robotic surgical assembly 100 and an electromechanical surgicalinstrument 200 coupled thereto. In some embodiments, the roboticsurgical assembly 100 may be removably attached to a slide rail 40 ofone of the surgical robotic arms 2, 3. In certain embodiments, therobotic surgical assembly 100 may be fixedly attached to the slide rail40 of one of the surgical robotic arms 2, 3.

Operating console 5 includes a display device 6, which is set up todisplay three-dimensional images; and manual input devices 7, 8, bymeans of which a clinician (not shown), is able to telemanipulate therobotic arms 2, 3 in a first operating mode, as known in principle to aperson skilled in the art. Each of the robotic arms 2, 3 may be composedof any number of members, which may be connected through joints. Therobotic arms 2, 3 may be driven by electric drives (not shown) that areconnected to control device 4. The control device 4 (e.g., a computer)is set up to activate the drives, for example, by means of a computerprogram, in such a way that the robotic arms 2, 3, the attached roboticsurgical assembly 100, and thus the electromechanical surgicalinstrument 200 (including the electromechanical end effector, not shown)execute a desired movement according to a movement defined by means ofthe manual input devices 7, 8. The control device 4 may also be set upin such a way that it regulates the movement of the robotic arms 2, 3and/or of the drives.

The robotic surgical system 1 is configured for use on a patient “P”positioned (e.g., lying) on a surgical table “ST” to be treated in aminimally invasive manner by means of a surgical instrument, e.g., theelectromechanical surgical instrument 200. The robotic surgical system 1may also include more than two robotic arms 2, 3, the additional roboticarms likewise connected to the control device 4 and telemanipulatable bymeans of the operating console 5. A surgical instrument, for example,the electromechanical surgical instrument 200 (including theelectromechanical end effector thereof), may also be attached to anyadditional robotic arm(s).

The control device 4 may control one or more motors, e.g., motors (Motor1 . . . n), each motor configured to drive movement of the robotic arms2, 3 in any number of directions. Further, the control device 4 maycontrol an instrument drive unit 110 including motors 52, 54, 56 and 58of a motor pack 50 (FIGS. 2, 7 and 17-21A) disposed within a sterilebarrier housing 130 of the robotic surgical assembly 100. The motors 52,54, 56 and 58 of the motor pack 50 drive various operations of an endeffector of the electromechanical surgical instrument 200. The motors52, 54, 56 and 58 may include a rotation motor, such as, for example, acanister motor. One or more of the motors 52, 54, 56 and 58 may beconfigured to drive a relative rotation of the electromechanicalsurgical instrument 200, or components thereof, along a longitudinalaxis “X” thereof. In some embodiments, each motor of motor pack 50 canbe configured to actuate a drive screw 340 (or, for example, a lineardrive, a capstan, etc.) which is operatively connected to a drive rod ora lever arm to effect operation and/or movement of the electromechanicalend effector of the electromechanical surgical instrument 200.

In accordance with the present disclosure, the electromechanicalsurgical instrument 200 is rotated about a longitudinal axis of rotationthereof by a motor 44 (e.g., in one embodiment, a fifth axis motor, seeFIG. 24) having a rotation axis that is offset a radial distance fromthe longitudinal axis of rotation of the electromechanical surgicalinstrument 200.

For a detailed discussion of the construction and operation of a roboticsurgical system, reference may be made to U.S. Patent ApplicationPublication No. 2012/0116416, filed on Nov. 3, 2011, entitled “MedicalWorkstation,” the entire contents of which are incorporated by referenceherein.

With continued reference to FIG. 1, the robotic surgical system 1includes the robotic surgical assembly 100 that is coupled with or tothe robotic arm 2 or 3, and the electromechanical surgical instrument200 that is coupled to the robotic surgical assembly 100. The roboticsurgical assembly 100 transfers power and actuation forces from itsmotors to driven members of the electromechanical surgical instrument200 to ultimately drive movement of components of the end effector ofelectromechanical surgical instrument 200, for example, a movement of aknife blade (not shown) and/or a closing and opening of jaw members ofthe end effector, an articulation/rotation/pitch/yaw of the endeffector, and/or the actuation or firing of a stapler. The roboticsurgical assembly 100 may also be configured for the activation orfiring of an electrosurgical energy-based instrument or the like (e.g.,cable drives, pulleys, friction wheels, rack and pinion arrangements,etc.).

Turning now to FIGS. 2-6, the robotic surgical assembly 100 isconnectable to an interface panel or carriage 42 which is slidablymounted onto the rail 40. The carriage 42 supports or houses a motor 44(see FIG. 24) that receives controls and power from the control device4. The carriage 42 may be moved along the rail 40 via a motor drivenchain or belt 41 (see FIG. 3) or the like. Alternatively, with referenceto FIGS. 32 and 33, the carriage 42 may be moved along the rail 40 via athreaded rod/nut arrangement. For example, the carriage 42 may support athreaded nut or collar 42 a which receives a threaded rod 40 atherethrough. In use, as the threaded rod 40 a is rotated, the threadedcollar 42 a (for example, see FIGS. 32 and 33), and in turn, thecarriage 42 are caused to be translated along the rail 40. A coupling 46(see FIG. 24), or the like, is connected to a drive shaft of motor 44,and may be rotated clockwise or counter clockwise upon an actuation ofthe motor 44. While a chain/belt 41 or threaded rod and collararrangement 40 a/42 a are shown and described, it is contemplated thatany other systems capable of achieving the intended function may be used(e.g., cable drives, pulleys, friction wheels, rack and pinionarrangements, etc.).

With reference to FIGS. 2-6 and 17-21A, the carriage 42 includes acoupling flange 43 extending or projecting from a rear panel 42 athereof and from the rail 40. With reference to FIGS. 2-4, the couplingflange 43 of the carriage 42 defines an opening or bore 43 atherethrough, and rotatably supports an instrument rotation gear orpulley 48. The pulley 48 has ring-shaped, non-circular, transverse,cross-sectional profile passage or opening therethrough (e.g.,substantially D-shaped, or the like) which defines a key-way fornon-rotational receipt of a drive transfer assembly 140 of the sterilebarrier housing 130. The pulley 48 is rotatably supported in thecoupling flange 43 by journal bearings or the like.

With reference momentarily to FIGS. 24-26, the carriage 42 may rotatablysupport motor axis gear or pulley 118 (e.g., a spur gear) and a tensiongear or pulley 120 within coupling flange 114. A drive belt 122 or thelike extends around the pulley 48, the motor axis pulley 118 and thetension pulley 120. The motor axis pulley 118 is connectable to thecoupling 46 of the motor 44, and is driven by the motor 44 upon anactuation thereof. Accordingly, in use, as the motor 44 is actuated, themotor 44 drives the coupling 46, which drives the motor axis pulley 118,to in turn drive the belt 122, and in turn, rotate the pulley 48.

With reference to FIGS. 2-6, a sterile shell or barrier 60 is providedwhich shrouds or covers the carriage 42. Shell 60 includes a rear shellportion 60 a configured and adapted to cover the rear panel 42 a of thecarriage 42, and an annular shell portion 60 b extending from rear shellportion 60 a and configured to cover the coupling flange 43 of thecarriage 42. The annular shell portion 60 b of the shell 60 defines anopening 60 c in registration with a passage or opening 48 a of thepulley 48 having a non-circular, transverse cross-sectional profile(e.g., substantially D-shaped, or the like). A sterile drape 61 or thelike may be secured or adhered to the shell 60 and may be pulled overthe rail 40 and the robotic arm 2 or 3 to establish and maintain asterile barrier between the patient “P,” the surgical field, and/or therobotic surgical system 1.

With reference to FIGS. 2 and 17-21A, the robotic surgical assembly 100includes a sterile barrier housing 130 configured to mate with orotherwise connect to the shell 60. The sterile barrier housing 130includes a hollow shell or body 132 defining a cavity therein. Thesterile barrier housing 130 pivotally or hingedly supports a proximalcap or cover 134 configured and adapted to selectively close a proximalend of the body 132. The sterile barrier housing 130 further includes adrive transfer assembly 140 supported on, or connected to, a distal endof the body 132.

The cavity of the body 132 of the sterile barrier housing 130 isconfigured to slidably receive a motor pack 50 or the like (see FIGS. 2,7, 8 and 17-21A) therein. The motor pack 50 may include four motors 52,54, 56, 58 arranged in a rectangular formation such that respectivedrive shafts 52 a, 54 a, 56 a, and 58 a thereof are all parallel to oneanother and all extend in a common direction. The drive shaft 52 a, 54a, 56 a, and 58 a of each motor 52, 54, 56, and 58, respectively, mayoperatively interface with a respective drive coupler 144 a, 146 a, 148a and 150 a of the drive transfer assembly 140 (see FIGS. 9-11). Themotor pack 50 may include four canister motors or the like, each havinga drive shaft having a non-circular transverse cross-sectional profile(e.g., substantially D-shaped, or the like).

For an exemplary motor pack 50 for use in the robotic surgical assembly100, reference may be made to U.S. Provisional Patent Application Ser.No. 62/181,817, filed on Jun. 19, 2015, entitled “Robotic SurgicalAssemblies,” the entire contents of which are incorporated by referenceherein.

With reference to FIGS. 8-11 and 17-20, a motor coupler 52 b, 54 b, 56b, and 58 b may be non-rotatably connected to a respective drive shaft52 a, 54 a, 56 a, and 58 a of each motor 52, 54, 56, and 58,respectively. Each motor coupler 52 b, 54 b, 56 b, and 58 b may have asubstantially tubular configuration defining a lumen therethrough havinga non-circular transverse cross-sectional profile. The lumen of eachmotor coupler 52 b, 54 b, 56 b, and 58 b is configured to non-rotatablyengage and/or receive respective drive shaft 52 a, 54 a, 56 a, and 58 aof each motor 52, 54, 56, and 58, respectively, wherein the lumens mayhave a substantially D-shaped transverse, cross-sectional profile.

Each motor coupler 52 b, 54 b, 56 b, and 58 b includes one or moredistally extending tab 52 c, 54 c, 56 c, and 58 c which is/areconfigured to engage a respective mating feature or slot 144 c, 146 c,148 c and 150 c of the drive couplers 144 a, 146 a, 148 a and 150 a ofthe drive transfer shafts 144, 146, 148 and 150 to transmit rotationalforces from the motors 52, 54, 56, and 58 to respective drive transfershafts 144, 146, 148 and 150 of the drive transfer assembly 140 in themanner of an “oldham coupling.” This oldham-type coupling limitsbacklash and enables autocorrecting when components thereof are slightlymisaligned with one another. In some embodiments, one or more of thesetabs and/or slots may have complementary v-shaped configurations. It iscontemplated that any rotational force transmitting feature may beprovided at the distal end of the motor couplers 52 b, 54 b, 56 b, and58 b. In use, as any one of the motors 52, 54, 56, and 58 is activatedto rotate a respective drive shaft 52 a, 54 a, 56 a, and 58 a, theparticular drive shaft drive shaft 52 a, 54 a, 56 a, and 58 a transmitsthe rotation to the respective motor coupler 52 b, 54 b, 56 b, and 58 b,which in turn, transmits the rotation (via tabs 52 c, 54 c, 56 c, and 58c) to the respective drive couplers 144 a, 146 a, 148 a and 150 a of thedrive transfer shafts 144, 146, 148 and 150 of the drive transferassembly 140. Such an arrangement and coupling permits a degree offlotation of the motor couplers 52 b, 54 b, 56 b, and 58 b and the drivecouplers 144 a, 146 a, 148 a and 150 a in any radial direction relativeto a longitudinal axis thereof.

With reference to FIGS. 9-12 and 17-21A, the drive transfer assembly 140of the sterile barrier housing 130 includes a body portion 142 extendingfrom the distal end of the body 132. The body portion 142 of the drivetransfer assembly 140 has a non-circular form (e.g., substantiallyD-shaped, as illustrated) outer profile for keyed receipt within acomplementary non-circular (e.g., D-shaped, as illustrated) passage oropening 48 a of the pulley 48 of the carriage 42. While a D-shapedtransverse cross-sectional profile is shown and described, anynon-circular transverse cross-sectional profile may be used to provide akeyed connection, including and not limited to hex, Allen, star, cross,double “D”, “T”, torx, val, phillips, helix profiles.

The drive transfer assembly 140 rotatably supports at least one, and asshown in FIGS. 11 and 18-20, four drive transfer shafts (only drivetransfer shafts 144 and 148 being shown). As illustrated, a proximal endof each drive transfer shaft (e.g., 144 and 148) non-rotatably supportsa respective drive coupler (e.g., 144 a and 148 a, respectively), viathe motor couplers 52 b, 54 b, etc., which are configured and adaptedfor non-rotatable connection to a drive shaft 52 a, 54 a, 56 a, and 58 aof a respective motor 52, 54, 56 and 58 of motor pack 50. In particular,each drive coupler 144 a, 146 a, 148 a and 150 a is translatablysupported on respective drive transfer shaft 144, 146, 148 and 150 via apin-slot arrangement such that the couplers 144, 146, 148 and 150 mayfloat on respective drive transfer shaft 144, 146, 148 and 150. Withparticular reference to FIG. 9, each drive coupler 144 a, 146 a, 148 aand 150 a defines a respective mating feature 144 c, 146 c, 148 c and150 c configured to receive and transmit rotational forces fromrespective drive shafts 52 a, 54 a, 56 a, and 58 a of the motors 52, 54,56 and 58 of the motor pack 50.

A distal end of each drive transfer shaft 144, 146, 148 and 150 supportsa respective drive coupler 144 b, 146 b, 148 b and 150 b, which areconfigured and adapted for non-rotatable connection to proximal couplers310 of drive assemblies 300 of the electromechanical surgical instrument200. It is contemplated that each drive coupler 144 b, 146 b, 148 b and150 b may resemble a crown gear or the like.

A respective biasing member 144 d, 146 d, 148 d and 150 d (e.g.,compression spring) may be interposed between the drive couplers 144 a,146 a, 148 a and 150 a and the drive couplers 144 b, 146 b, 148 b and150 b, wherein the biasing members 144 d, 146 d, 148 d and 150 dmaintain the drive couplers 144 a, 146 a, 148 a and 150 a in an extendedcondition, and maintain a distal floating plate 173 in an extendedcondition, as will be described in greater detail below.

While FIG. 11 only illustrates the drive transfer shaft 144 connected tothe drive shaft 52 b (of the motor 52), in the interest of brevity, eachof the remaining drive transfer shafts 146, 148 and 150 are constructedin the same or similar manner as the drive transfer shaft 144 and willnot be described in great detail herein. Additionally, as seen in FIG.21A, a biasing member 175, in the form or a spring, may act on thedistal floating plate 173 to help maintain the distal floating plate 173in an extended condition.

In use, as the motors 52, 54, 56, and 58 of the motor pack 50 areactuated, rotation of the drive shafts 52 a, 54 a, 56 a, and 58 a of themotors 52, 54, 56, and 58, respectively, is transferred to the proximalcouplers 310 of the drive assemblies 300 of the electromechanicalsurgical instrument 200 via respective drive transfer shafts 144, 146,148 and 150.

With reference to FIGS. 10, 25 and 28, the body portion 142 of the drivetransfer assembly 140 includes a distally extending tab or tongue 142 d,forming a plug. The plug 142 d is configured to support electricalconnectors therein for enabling electrical interconnection between themotor pack 50 contained in the sterile barrier housing 130 and anelectrical connector 220 (FIG. 13) of the electromechanical surgicalinstrument 200.

As illustrated in FIGS. 2, 9, 10 and 17-21A, the robotic surgicalassembly 100 includes a lock ring or collar 160 rotatably supported onthe distal end of the body 132 of the sterile barrier housing 130. Thelock collar 160 projects distally from the body 132 of the sterilebarrier housing 130, and defines an internal thread 160 a (see FIGS.17-21A) configured for threadable connection to a proximal ringconnector 171 (see FIGS. 2, 6 and 17-21A) of the sterile barrier collarassembly 170, as will be described in great detail below.

With reference to FIGS. 9 and 10, the lock ring or collar 160non-rotatably supports a tactile feedback ring 161 therewithin. Thetactile feedback ring 161 includes one or more radially outwardlyprojecting nubs or ribs 161 a configured to be received in acorresponding recess 160 b (FIG. 10) defined in an inner surface of thelock ring or collar 160. The tactile feedback ring 161 further includesone or more dovetail connectors 161 b or the like projecting radiallyinwardly therefrom and configured for coupling or mating with acorresponding recess 142 a formed in the body portion 142 of the drivetransfer assembly 140.

In use, as a clinician rotates the drive transfer assembly 140, about alongitudinal axis thereof, to a desired angular orientation, the nub orrib 161 a of the tactile feedback ring 161 selectively enterscorresponding recesses 160 b of the lock ring or collar 160 to providetactile feedback to the clinician as to the angular orientation of thedrive transfer assembly 140. It is contemplated that the recesses 160 bof the lock ring or collar 160 and the nubs or ribs 161 a of the tactilefeedback ring 161 are provided whereby tactile feedback is provided forevery 90° angular orientation of the drive transfer assembly 140, or anyother desired or envisioned angular orientation.

Turning now to FIGS. 2, 13 and 17-21A, the robotic surgical assembly 100includes a sterile barrier collar assembly 170 connectable to theannular shell 60 b of the shell 60 and extendable through the D-shapedpassage or opening 48 a of the pulley 48. Specifically, the sterilebarrier collar assembly 170 includes a tubular sleeve body 172 having anon-circular, transverse cross-sectional outer profile (e.g.,substantially D-shaped, or the like), and an inner bore 172 a having acomplementary non-circular, transverse cross-sectional profile (e.g.,substantially D-shaped, or the like).

The sterile barrier collar assembly 170 further includes a semi-annularcoupling cuff 176 supported on or otherwise secured to a distal end ofthe tubular sleeve body 172. The coupling cuff 176 includes, asillustrated at least in FIG. 13, a U-shaped body portion 176 a having anopen side edge or instrument opening 176 b that opens distally andlaterally, and a pair of opposed side arms 176 c. Each side arm 176 c ofthe body portion 176 a includes a ramp surface 176 d formed in orprojecting from an inner juxtaposed surface thereof. Each ramp 176 dincreases in height from a distal end (near the open side edge 176 b) toa proximal end (near a backspan of the body portion 176 a). It iscontemplated that each ramp 176 d may be angled at approximately 10°relative to a planar distal surface of the coupling cuff 176. Each sidearm 176 c of the body portion 176 a further includes a recess or channel176 e formed in a surface thereof which is configured to slidablyreceive a respective arm or tab 173 a of the distal floating plate 173that is connected to or otherwise extending from a distal end of thetubular sleeve body 172.

The sterile barrier collar assembly 170 further includes the distalfloating plate 173, as mentioned above. The distal floating plate 173includes a pair of parallel arms or tabs 173 a extending therefrom, andwhich are dimensioned to extend through, and project from, the recessesor channels 176 e of the coupling cuff 176.

The distal floating plate 173 further defines a pattern of openings thatmay include and is not limited to a radial or a rectangular array ofopenings 173 b therein through which the distal end of each drivetransfer shaft 144, 146, 148 and 150 of the drive transfer assembly 140extends. Specifically, the drive couplers 144 b, 146 b, 148 b and 150 bof respective drive transfer shafts 144, 146, 148 and 150 are rotatablyseated in a respective opening 173 b of the distal floating plate 173.

In operation, with the coupling cuff 176 connected to distal end of thetubular sleeve body 172, the biasing members 144 d, 146 d, 148 d and 150d press the drive couplers 144 a, 146 a, 148 a and 150 a of respectivedrive transfer shafts 144, 146, 148 and 150 to an extended condition,which in turn, press against the distal floating plate 173 to maintainthe distal floating plate 173 in the extended condition, whereby thepair of parallel arms or tabs 173 a of the distal floating plate 173extend through and project from the recesses or channels 176 e of thecoupling cuff 176.

The sterile barrier collar assembly 170 functions to maintain a sterilebarrier between sterile components (e.g., the sterile barrier housing130, the electromechanical surgical instrument 200, etc.) andnon-sterile components (e.g., the robotic arms 2, 3, the motor pack 50,etc.). Specifically, the sterile barrier collar assembly 170 extendsthrough the opening of the annular shell 60 b of the shell 60, and, morespecifically, through the D-shaped passage or opening 48 a of the pulley48 of the carriage 42. In operation, as the motor 44 of the interfacepanel 42 is actuated, the motor 44 drives the pulley 48 (as describedabove), which in turn, causes the sterile barrier collar assembly 170 torotate. With the drive transfer assembly 140 extending through and keyedto the inner bore 172 a of the tubular sleeve body 172 of the sterilebarrier collar assembly 170, as the sterile barrier collar assembly 170is rotated, the drive transfer assembly 140 is rotated, which in turnrotates the motor pack 50, which is rotatably retained or contained insterile barrier housing 130.

Turning now to FIGS. 13-21A, the electromechanical surgical instrument200 is shown and will be described. The electromechanical surgicalinstrument 200 may have a surgical instrument or end effector (notshown) secured to or securable to a distal end thereof. Theelectromechanical surgical instrument 200 is configured to transferrotational forces/movement supplied by the robotic surgical assembly 100(e.g., via the motors 52-58 of the motor pack 50) into longitudinalmovement of the drive members 380 to effect various functions thereof.

The electromechanical surgical instrument 200 includes a housingassembly 210 including a housing 212 defining at least one cavity orbore 212 a therein which is configured to receive a drive assembly 300therein. In accordance with the present disclosure, the bore 212 a ofthe housing 212 is configured to operatively support four separate driveassemblies 300 therein. It is contemplated that the bore 212 a may beconfigured to define four separate discrete or interconnected boreportions with each portion operatively supporting a separate one of thefour drive assemblies 300.

As illustrated in FIGS. 15 and 16, each portion of the bore 212 a of thehousing 212 defines a respective longitudinally extending groove orchannel 212 b therein. Each channel 212 b is configured to slidinglyaccept a rail or tab 350 b extending radially from a drive nut 350 of arespective drive assembly 300, as will be described in greater detailbelow.

The housing 212 further includes ramped camming surfaces 218 disposed onopposed side surfaces thereof for transverse connection/disconnectionwith the ramp surfaces 176 d of the U-shaped body portion 176 a of thecoupling cuff 176 of the sterile barrier collar assembly 170 (FIG. 13)(e.g., side-loading, described in greater detail below), to connect theelectromechanical surgical instrument 200 to the robotic surgicalassembly 100. When the electromechanical surgical instrument 200 isfully connected to the robotic surgical assembly 100, the proximalcouplers 310 of the drive assemblies 300 of the electromechanicalsurgical instrument 200 come into registration with and are connected torespective drive transfer shafts 144, 146, 148 and 150 of the drivetransfer assembly 140 of the robotic surgical assembly 100.

The housing 212 of the housing assembly 210 of the electromechanicalsurgical instrument 200 supports an electrical connector 220 (FIG. 13)configured for selective connection to the plug 146 of the driveassembly 140 of the robotic surgical assembly 100, as described above.The electromechanical surgical instrument 200 may include electronics,including, and not limited to, a memory (for storing identificationinformation, usage information, and the like), wired or wirelesscommunication circuitry (for receiving and transmitting data orinformation from/to the electromechanical surgical instrument 200,from/to control device 4, and/or from/to a remote central processingsystem). The robotic surgical assembly 100 may be configured to permitpassage or routing of a dedicated electrocautery cable or the like foruse and connection to an electrosurgical based electromechanicalsurgical instrument (e.g., for ablation, coagulation, sealing, etc.) Theelectrical connector 220 may include and is not limited to conductiveconnectors, magnetic connectors, resistive connectors, capacitiveconnectors, Hall sensors, reed switches or the like.

With continued reference to FIGS. 13-21A, the housing assembly 210 ofthe electromechanical surgical instrument 200 includes a plurality ofdrive assemblies 300. In the illustrated embodiment, theelectromechanical surgical instrument 200 includes four drive assemblies300; however the electromechanical surgical instrument 200 may includemore (e.g., five or six) or fewer (e.g., three) drive assemblies 300without departing from the scope of the present disclosure.

Each drive assembly 300 includes a proximal coupler 310, a proximalbearing 320, a drive screw 340, a drive nut 350, a biasing element 370,and a drive member (e.g., a drive rod or drive cable) 380. The proximalcoupler 310 of each drive assembly 300 is configured to meshingly engagewith a respective drive coupler 144 b, 146 b, 148 b and 150 b of thedrive transfer shafts 144, 146, 148 and 150 of the drive transferassembly 140. In operation, rotation of the drive transfer shafts 144,146, 148 and 150 of the drive transfer assembly 140, as described above,results in rotation of respective proximal coupler 310 of respectivedrive assembly 300.

The proximal coupler 310 of each drive assembly 300 is keyed to orotherwise non-rotatably connected to a proximal end of a respectivedrive screw 340. Accordingly, rotation of the proximal coupler 310results in a corresponding rotation of a respective drive screw 340.

Each proximal bearing 320 is disposed about a proximal portion of arespective drive screw 340 adjacent a proximal end of the housing 212 ofthe housing assembly 210. A distal end or tip of each drive screw 340may be rotatably disposed or supported in a respective recess 212 cdefined in a distal end of the housing 212 (see FIG. 15).

The drive screw 340 includes a threaded body or shaft portion 340 a, anddefines a longitudinal axis “A-A” extending through a radial centerthereof (see FIG. 14). In use, rotation of the proximal coupler 310, asdescribed above, results in rotation of a respective drive screw 340about longitudinal axis “A-A”, in a corresponding direction and rate ofrotation.

The drive nut 350 (or capstan) includes a threaded aperture 350 aextending longitudinally therethrough, which is configured tomechanically engage the threaded shaft portion 340 a of the drive screw340. The drive nut 350 is configured to be positioned on the drive screw340 in a manner such that rotation of the drive screw 340 causeslongitudinal movement of the drive nut 350. That is, the drive nut 350and the drive screw 340 are threadingly engaged with each other.Moreover, rotation of the proximal coupler 310 in a first direction(e.g., clockwise) causes the drive nut 350 to move in a firstlongitudinal direction (e.g., proximally) along the drive screw 340, androtation of the proximal coupler 310 in a second direction (e.g.,counter-clockwise) causes the drive nut 350 to move in a secondlongitudinal direction (e.g., distally) with respect to the drive screw340.

Each drive nut 350 includes a retention pocket formed in an engagementtab 350 c formed therein that is disposed adjacent the threaded aperture350 a thereof. Each retention pocket is configured to retain a proximalend 380 a of a respective drive member 380, as discussed in furtherdetail below.

Each drive nut 350 includes a tab 350 b extending radially from andlongitudinally along an outer surface thereof. The tab 350 b of eachdrive nut 350 is configured to be slidably disposed in a longitudinallyextending channel 212 b formed in the bore 212 a of the housing 212. Thetab 350 b of each drive nut 350 cooperates with a respective channel 212b of the bore 212 a of the housing 212 to inhibit or prevent the drivenut 350 from rotating about longitudinal axis “A-A” as the drive screw340 is rotated.

Each drive nut 350 includes an engagement portion 350 c disposedadjacent a radially inward surface thereof, which is configured tomechanically engage or retain a proximal portion 380 a of a respectivedrive member 380. In operation, as the drive nuts 350 are axiallydisplaced along the drive screw 340, the drive nuts 350 transmitconcomitant axial translation of the drive member 380.

A biasing element 370, e.g., a compression spring, is configured toradially surround a distal portion of the threaded shaft portion 340 aof each drive screw 340. Each biasing element 370 is interposed betweena respective drive nut 350 and a distal surface of the housing 212 ofthe housing assembly 210.

Each drive member 380 extends distally from a respective drive nut 350,through a respective central bore or channel of the housing 212 of thehousing assembly 210, and is configured to mechanically engage a portionof a surgical instrument, e.g., end effector, of the electromechanicalsurgical instrument 200.

In operation, longitudinal translation of at least one drive member 380is configured to drive a function of the end effector of theelectromechanical surgical instrument 200. For example, a distaltranslation of a particular drive member 380 may be configured toapproximate a pair of jaw members of the end effector with respect tothe other, and a proximal translation of the same drive member 380 maybe configured to move at least one jaw member away from the other jawmember, for instance. Additionally, a distal translation of anotherdrive member 380 of the electromechanical surgical instrument 200 may beconfigured to articulate the pair of jaw members of the end effector ina first direction, and a proximal translation of the another drivemember 380 may be configured to articulate the pair of jaw members ofthe end effector in a second direction.

In accordance with the present disclosure, a distal portion of at leastone of the drive members 380 may include a flexible portion, while aproximal portion of the drive members 380 are rigid, such that theflexible distal portion may follow a particular path through theelectromechanical surgical instrument 200. Accordingly, the biasingmembers 370 function to maintain the drive member 380 in tension toprevent slack or to reduce the amount of slack in the flexible distalportion of the drive member 380.

During a use of the electromechanical surgical instrument 200 (i.e.,when motor(s) 52, 54, 56 and 58 of the robotic surgical assembly 100, orother powered drives, are used to rotate proximal couplers(s) 310),rotation of the proximal coupler 310 results in a corresponding rotationof the drive screw 340. Rotation of the drive screw 340 causeslongitudinal translation of the drive nut 350 due to the engagementbetween the threaded portion 340 a of the drive screw 340 and thethreaded aperture of the drive nut 350. As discussed above, thedirection of longitudinal translation of the drive nut 350 is determinedby the direction of rotation of the proximal coupler 310, and thus, thedrive screw 340. For example, proximal translation of the drive screw340 results in a corresponding proximal translation of a respectivedrive member 380 which is engaged with the drive screw 340.

Additionally, when one drive nut 350, from a first drive assembly 300,moves in a first longitudinal direction (e.g., proximally), it isenvisioned that a drive nut 350, from a different drive assembly 300, isforced to correspondingly move in a second, opposite longitudinaldirection (e.g., distally). Such configurations function to compensatefor any slack in the drive members 380. It is contemplated and inaccordance with the present disclosure that each drive nut 350 may beindependently driven.

While end effectors have been described in here as including a jawassembly, the use of other end effectors are additionally oralternatively possible. Reference may be made to commonly ownedInternational Patent Application No. PCT/US14/61329, filed on Oct. 20,2014 entitled “Wrist and Jaw Assemblies for Robotic Surgical Systems,”the entire contents of which are incorporated herein by reference, for adetailed discussion of illustrative examples of the construction andoperation of end effectors for use with or connection toelectromechanical surgical instrument 200.

With reference to FIGS. 13, 21 and 35, the housing 212 of the housingassembly 210 of the electromechanical surgical instrument 200 supportsat least one, desirably a pair of release levers or paddles 214 onopposed sides thereof. Each release paddle 214 includes a first end 214a pivotally connected to the housing 212, and a second end 214 b movableto/from an outer surface of the housing 212. The second end 214 b ofeach release paddle 214 defines a tapered camming surface 214 cconfigured to act on a respective arm or tab 173 a of the distalfloating plate 173 of the sterile barrier collar assembly 170, todisengage the electromechanical surgical instrument 200 from the roboticsurgical assembly 100. Specifically, when the electromechanical surgicalinstrument 200 is connected to semi-annular coupling cuff 176 of thesterile barrier collar assembly 170, arms or tabs 173 a of the distalfloating plate 173 are aligned and in registration with respectivepaddles 214 of the electromechanical surgical instrument 200. Further,the free ends of the arms or tabs 173 a of the distal floating plate 173act on respective tapered camming surfaces 214 c of the paddles 214 topress or urge the paddles 214 outwardly.

With continued reference to FIGS. 13, 21A, and 35, a connection of theelectromechanical surgical instrument 200 to the robotic surgicalassembly 100 is shown and will be described. Initially, as describedbriefly above, the sterile barrier collar assembly 170 is connected tothe annular shell 60 b of the shell 60, the motor pack 50 is loaded inthe cavity 132 a of the body 132 of the sterile barrier housing 130, andthe drive transfer assembly 140 of the sterile barrier housing 130 ofthe robotic surgical assembly 100 is connected to the shell 60.

The electromechanical surgical instrument 200 is then connected to thecoupling cuff 176 of the sterile barrier collar assembly 170 by firstaligning the ramped camming surfaces 218 of the housing 212 of theelectromechanical surgical instrument 200 with the corresponding rampsurface 176 d of the coupling cuff 176. As seen in FIGS. 21B-21D, theelectromechanical surgical instrument 200 is then transversely moved(e.g., side loaded) relative to the robotic surgical assembly 100 suchthat the ramped camming surfaces 218 of the electromechanical surgicalinstrument 200 cams the electromechanical surgical instrument 200upwardly (proximally) along the ramp surface 176 d of the coupling cuff176 until the housing 212 of the electromechanical surgical instrument200 is fully received or seated in the coupling cuff 176.

As the electromechanical surgical instrument 200 is transversely movedinto the coupling cuff 176, as described above, the housing 212 is urgedupwardly (proximally) into contact with inner shoulders 173 c, 173 d(FIG. 21A) of the distal floating plate 173 to urge the distal floatingplate 173 proximally against the distal spring bias of the distalfloating plate 173. Also, when the electromechanical surgical instrument200 is properly connected to the robotic surgical assembly 100, theproximal couplers 310 of the electromechanical surgical instrument 200come into registration with (e.g., spring biased) and are connected torespective drive transfer shafts 144, 146, 148 and 150 of the drivetransfer assembly 140 of the robotic surgical assembly 100.

Disconnection of the electromechanical surgical instrument 200 from therobotic surgical assembly 100 includes pressing the paddles 214 of theelectromechanical surgical instrument 200 toward the housing 212 wherebythe tapered camming surfaces 214 c of the paddles 214 act on the freeends of the arms or tabs 173 a of the distal floating plate 173. As thepaddles 214 act on the free ends of the arms or tabs 173 a, the paddles214 urge the distal floating plate 173 proximally, whereby the drivecouplers 144 b, 146 b, 148 b and 150 b of the drive transfer shaft 144,146, 148 and 150 are urged proximally, against the bias of respectivebiasing members 144 d, 146 d, 148 d and 150 d, to separate or disengagethe drive couplers 144 b, 146 b, 148 b and 150 b from respectiveproximal gears or couplers 310 of the electromechanical surgicalinstrument 200 (FIG. 20). Thereafter, the electromechanical surgicalinstrument 200 may be transversely removed or disconnected from therobotic surgical assembly 100.

As illustrated in FIG. 21A, the tubular sleeve body 172 of the sterilebarrier collar assembly 170 includes a pair of opposed deflectablefingers 172 b extending in an axial direction. Each finger 172 bterminates in a free end having an outer angled surface 172 c extendingradially outward, and an inner angled surface 172 d extending radiallyoutward. Further, the proximal ring connector 171 defines an innerannular, angled surface 171 a oriented at an angle complementary to theouter angled surface 172 c of the tubular sleeve body 172. Also, adistal nose of the sterile barrier housing 130 defines an outer annular,angled surface 130 a oriented at an angle complementary to the innerangled surface 172 d of the tubular sleeve body 172.

In use, with the tubular sleeve body 172 snapped into the proximal ringcollar 171, the proximal ring collar 171 is connected to the lock ringcollar 160 by inserting a proximal end of the proximal ring collar 171into the lock ring collar 160 and rotating the lock ring collar 160 todraw-in and threadably connect with the proximal ring collar 171. As thelock ring collar 160 is rotated to draw-in the proximal ring collar 171,the inner annular, angled surface 171 a of the proximal ring collar 171acts on the outer angled surface 172 c of the deflectable fingers 172 bof the tubular sleeve body 172 to pinch or trap the deflectable fingers172 b of the tubular sleeve body 172 against the outer annular, angledsurface 130 a of the distal nose of the sterile barrier housing 130. Inthis manner, tightening rotation of lock ring collar 160 approximatesdrive transfer assembly 140 and proximal ring collar 171 and mates drivetransfer assembly 140 to tubular sleeve body 172

With continued reference to FIG. 21A, a sealing member 177, in the formof an O-ring, gasket or the like, may be interposed between an outerannular flange of outer housing portion 130 and a proximal ledge orsurface of the proximal ring collar 171.

Turning now to FIGS. 22-35, a lock ring or collar according to anotherembodiment of the present disclosure is shown and described, and isgenerally designated as the lock ring or collar 460. Additionally, asshown in FIGS. 22-35, a sterile barrier collar assembly according toanother embodiment of the present disclosure is shown and described, andis generally designated as sterile barrier collar assembly 470. In FIGS.22-35, like reference numerals have been used to identify like parts asin FIGS. 1-21A. Also, in the interest of brevity, only the differencesbetween the robotic surgical assembly 100 having the lock ring or collar160 and the sterile barrier collar assembly 170 (FIGS. 1-21A) and therobotic surgical assembly 100 having the lock ring or collar 460 and thesterile barrier collar assembly 470 (FIGS. 22-35), will be described indetail herein below.

As illustrated in FIGS. 21A-35, the robotic surgical assembly 100 mayinclude the lock ring or collar 460 rotatably supported on the distalend of the body 132 of the sterile barrier housing 130. The lock collar460 projects distally from the body 132 of the sterile barrier housing130, and defines an internal thread 460 a (see FIGS. 33 and 35, 27)configured for threadable connection to a sterile barrier collarassembly 470. A distal-most surface of the lock collar 460 defines aseries of notches or recesses 460 b therein. The recesses 460 b mayextend radially around the distal-most surface of the lock collar 460.The recesses 460 b may include four sets of three recesses, with one setof recesses located 90° apart (or substantially 90° apart) from oneanother.

The robotic surgical assembly 100 may further include a sterile barriercollar assembly 470 connectable to the annular shell 60 b of the shell60 and extendable through the D-shaped passage or opening 48 a of thepulley 48 (see FIGS. 26 and 27). Specifically, the sterile barriercollar assembly 470 includes a tubular sleeve body 172 having anon-circular, transverse cross-sectional outer profile (e.g.,substantially D-shaped, or the like), and an inner bore 472 a having acomplementary, non-circular, transverse cross-sectional profile (e.g.,substantially D-shaped, or the like). An outer surface of a proximalportion of tubular sleeve body 472 defines a thread 472 b therein,wherein the thread 472 b is formed in at least one radial portion of thetubular sleeve body 472. The proximal portion of the tubular sleeve body472 includes a pair of opposed, deflectable tabs 472 c projectingradially outward, and increasing in height from a proximal end to adistal end thereof.

The sterile barrier collar assembly 470 further includes a ring flange474 supported on the tubular sleeve body 472. The ring flange 474extends radially outward from the tubular sleeve body 472. The ringflange 474 includes a pair of opposed, deflectable tabs 474 a projectingfrom a proximal surface of the ring flange 474. The deflectable tabs 474a of the ring flange 474 are configured for selective receipt in therecesses 460 b formed in the lock collar 460. As collar 460 is rotatedto secure the electromechanical surgical instrument 200 to the roboticsurgical assembly 100, a tactile and/or audible feedback is providedbetween the deflectable tabs 474 a of the ring flange 474 and therecesses 460 b of the lock collar 460 to provide an indication that theelectromechanical surgical instrument 200 is secured to the roboticsurgical assembly 100.

It is contemplated that a sheet of polymeric material, constituting adrape or the like (not shown), may be sandwiched or captured (or bonded,elastically mated, or snap latched) between the distal-most surface ofthe lock collar 460 of the sterile barrier housing 130 and the proximalsurface of the ring flange 474 of the sterile barrier collar assembly470. The drape may be extended over the sterile barrier housing 130,over the rail 40 and over the robotic arms 2, 3.

With reference to FIG. 36, one embodiment of a robotic surgical systemincludes a robotic surgical assembly 500 having fourindependently-controlled motors 52, 54, 56 and 58, and anelectromechanical surgical instrument 250 including a drive system 256having four drive assemblies 256 a-256 d, with each drive assemblyselectively connectable to the respective motor 52, 54, 56 and 58 of therobotic surgical assembly 500, for example, as described above withrespect to robotic surgical assembly 100. The electromechanical surgicalinstrument 250 is similar to electrosurgical instrument 200 and isdescribed herein only to the extent necessary to describe thedifferences in construction and operation thereof.

The electromechanical surgical instrument 250 includes an end effector252 (shown in FIG. 36 in an open position) selectively supported on adistal end thereof and an instrument housing 253 supported on a proximalend thereof. While the end effector 252 may include a jaw assembly orthe like, the use of other end effectors are additionally oralternatively possible. Reference may be made to commonly ownedInternational Patent Application No. PCT/US14/61329, filed on Oct. 20,2014 entitled “Wrist and Jaw Assemblies for Robotic Surgical Systems,”U.S. Pat. No. 8,636,192, or 8,925,786, the entire contents of each ofwhich are incorporated by reference herein, for a detailed discussion ofillustrative examples of the construction and operation of end effectorsfor use with or connection to the electromechanical surgical instrument250.

The instrument housing 253 supports a detachment assembly 254 and adrive assembly 256. The detachment assembly 254 includes release leversor paddles 254 a, 254 b on opposed sides of the instrument housing 253and which are operable to selectively separate the electromechanicalsurgical instrument 250 from the robotic surgical assembly 500. Eachpaddle 254 a, 254 b may include tapered camming surfaces (not shown)configured to act on tabs 566 b, 566 c of a floating plate 566 of asterile interface module 530 to disengage the electromechanical surgicalinstrument 250 from the robotic surgical assembly 500 as described ingreater detail below (see FIG. 43). The drive system 256 includes afirst drive assembly 256 a and second drive assemblies 256 b, 256 c, 256d that cooperate with one or more drive or connector members “CM,” suchas drive cables or drive rods, coupled to the end effector 252 of theelectromechanical surgical instrument 250 to manipulate and/or operatethe end effector 252. Each of the first and second drive assemblies 256a-256 d includes an engagement coupler 258 (e.g., a gear or the like)engagable with complementary instrument engagement ends or couplers(such as engagement couplers 568 e shown in FIG. 47) of the roboticsurgical assembly 500 described in greater detail below.

As mentioned above, the robotic surgical system 1 is configured for useon a patient “P” positioned (e.g., lying) on a surgical table “ST” to betreated in a minimally invasive manner by means of a surgicalinstrument, e.g., any one of the electromechanical surgical instrumentssuch as straight/articulatable instruments 200 and 250 (e.g., staplinginstrument, suturing instrument, electrocautery instrument, etc.),endoscope 250′ or grasper 250″ (FIG. 36). The robotic surgical system 1may include more than two robotic arms 2, 3, the additional robotic armslikewise being connected to the control device 4 and telemanipulatableby means of the operating console 5. A surgical instrument, for example,any one or more of electromechanical surgical instruments 200 (FIG. 2),250, 250′, and/or 250″ may also be attached to the additional roboticarm.

As mentioned above, the motor pack 50 may include four motors (e.g.,canister motors or the like with non-circular drive shafts) arranged ina formation so that each of the four motors extends in a commondirection and are in parallel with one another so as to interface withany one of the electromechanical surgical instruments 200 (FIG. 2), 250,250′, and/or 250″.

In general, the robotic surgical assembly 500 transfers power andactuation forces from one or more of its motors 52, 54 to one or more ofrespective driven members/drive assemblies 256 a-256 d of theelectromechanical surgical instrument 250 (e.g., keyed together via an“oldham coupling” arrangement or the like for transmitting rotationaland/or axial forces between the robotic surgical assembly 500 and theelectromechanical surgical instrument 250) to ultimately drive movementof one or more components of the end effector 252 of electromechanicalsurgical instrument 250. For example, the transfer of power/forces fromthe robotic surgical assembly 500 to the electromechanical surgicalinstrument 250 effectuates a movement of a knife blade (not shown), aclosing and opening of jaw members of the end effector 252, an actuationor firing of a stapler, an activation or firing of an electrosurgicalenergy-based instrument, and/or other functions thereof.

For a detailed discussion of the construction and operation of a similarrobotic surgical system having one or more of the same or similarcomponents for use with one or more components of the presentlydescribed robotic surgical system, reference may also be made to U.S.Patent Application Publication No. 2012/0116416, filed on Nov. 3, 2011,entitled “Medical Workstation,” the entire contents of which areincorporated by reference herein.

Turning now to FIGS. 36-47, the robotic surgical assembly 500 of therobotic surgical system 1 includes an instrument drive unit or housing510 supporting a motor assembly or motor pack 50. The housing 510 of therobotic surgical assembly 500 includes a connector assembly 540.

A ring member 550 having a sterile drape 552 secured thereto isprovided, wherein the ring member 550 permits passage of rotationalforces from the motor pack 50, and wherein the sterile drape 552 isconfigured to overlie the robotic surgical assembly 500 and the roboticarms 2, 3. The ring member 550 is configured for rotatable attachment toa distal end of the connector assembly 540 (e.g., via snap fit). Thesterile drape 552 can be arranged as desired above about the housing510, the robotic surgical assembly 500 and the robotic arms 2, 3 toprovide a sterile barrier between the various aforementioned componentsand/or the surgical site/fluids and the electromechanical surgicalinstruments 200 (FIG. 2), 250, 250′, and/or 250″.

A collar assembly or sterile interface module 530 is provided forselectively interconnecting the robotic surgical assembly 500 and anyone of the electromechanical surgical instruments 200 (FIG. 2), 250,250′, and/or 250″ similar to that described above with respect to thecoupling of the electromechanical surgical instrument 200 to roboticsurgical assembly 100 (e.g., side-loading). In general, sterileinterface module 530 functions to provide an interface between theinstrument drive unit or housing 510 and an electromechanical surgicalinstrument such as electromechanical surgical instrument 250. Thisinterface advantageously maintains sterility, provides a means totransmit electrical communication between the robotic surgical assembly500 and the electromechanical surgical instruments, provides a means fortransferring rotational force from the robotic surgical assembly 500 tothe electromechanical surgical instruments for performing a functionwith the electromechanical surgical instruments, and/or provides a meansto selectively attach/remove electromechanical surgical instruments tothe robotic surgical assembly 500 (e.g., for rapid instrument exchange).

The motor assembly 50 of the robotic surgical assembly 500 includes anynumber of motors 52, 54 (e.g., 2, 3, 4, 5, etc.) that couple to thesterile interface module 530 via a corresponding number of motorcouplers 52 b, 54 b (see FIG. 41) extending from the motors 52, 54.

As seen in FIG. 40, the collar assembly or sterile interface module 530includes electrical connectors 532 a, 532 b and an electrical ribbon 534coupled between the electrical connectors 532 a, 532 b to provideelectrical communication between the robotic surgical assembly 500 andany electromechanical surgical instrument, such as electromechanicalsurgical instrument 250, coupled thereto.

With reference to FIGS. 41-45, the sterile interface module 530 includesa body member 562 having an upper portion 562 a, an intermediate portion562 b, and a lower portion 562 c. The upper portion 562 a of the bodymember 562 defines a helical channel 562 d that extends around the upperportion 562 a from a shoulder 562 e of the upper portion 562 a. Theupper portion 562 a further includes a pair of attachment arms 562 f,562 g that extend proximally from the upper portion 562 a to secure thesterile interface module 530 to the connector assembly 540 of thehousing 510 of the robotic surgical assembly 500. The pair of attachmentarms 562 f, 562 g may be disposed in mirrored relation on opposed sidesof the upper portion 562 a.

The intermediate portion 562 b of the body member 562 includes a flange562 h and rotatably supports a rotatable collar 564 thereon. Therotatable collar 564 of the sterile interface module 530 defines ahelical channel 564 a that extends from a shoulder 564 b of therotatable collar 564. The helical channel 564 a of the rotatable collar564 and the shoulder 564 b of the rotatable collar 564 complement thehelical channel 562 d of the upper portion 562 a of the body member 562and the shoulder 562 e of the upper portion 562 a of the body member562. The rotatable collar 564 further includes gripping grooves 564 c tofacilitate user gripping and/or rotation of the rotatable collar 564relative to the body member 562 of the sterile interface module 530, asindicated by arrow “A” (described in greater detail below).

The lower portion 562 c of the body member 562 of the sterile interfacemodule 530 is in the form of a semi-annular coupling cuff that issupported on or otherwise secured to a distal end of the intermediateportion 562 b of the body member 562. The lower portion 562 c of thebody member 562 includes a U-shaped body having an instrument opening562 i defined between side arms 562 j, 562 k and opening distally andlaterally. The lower portion 562 c further includes a ramped surface 562x (FIG. 41) formed on an inner surface thereof that complements theramped camming surfaces 218 of the housing 212 of the electromechanicalsurgical instrument 250. The instrument opening 562 i is configured toreceive an electromechanical surgical instrument, such aselectromechanical surgical instrument 250, therein to removably securethe electromechanical surgical instrument 250 to the robotic surgicalassembly 500. The side arms 562 j, 562 k of the lower portion 562 cextend distally from the intermediate portion 562 b of the body member562 and are positioned to support the electromechanical surgicalinstrument 250 within the instrument opening 562 i of the lower portion562 c.

Similar to distal floating plate 173 described above with respect to therobotic surgical assembly 100, the sterile interface module 530 furtherincludes a floating plate 566 supported between the intermediate portion562 b of the body member 562 and the lower portion 562 c of the bodymember 562. The floating plate 566 of the sterile interface module ismovable between an uncompressed position or extended position and acompressed or retracted position. The floating plate 566 is springbiased distally toward the uncompressed position by a round spring(e.g., a wave spring, not shown) and by biasing members of drivetransfer assemblies (e.g., 568, 570) of the sterile interface module530. In the uncompressed position of the floating plate 566 of thesterile interface module 530, the floating plate 566 is spaced adistance “D” (see FIG. 43) from a bottom surface 562 e of theintermediate portion 562 b. The floating plate 566 includes a baseportion 566 and tabs 566 b, 566 c extending distally from the baseportion 566. The tabs 566 b, 566 c extend through the lower portion 562c of the body member 562. The floating plate 566 defines apertures 566d, 566 e therein that receive first and second drive transfer assemblies568, 570 of the sterile interface module 530. While a pair of drivetransfer assemblies 568, 570 are shown and described in detail herein,any number of drive transfer assemblies may be provided, such as, forexample, one, three, five, etc.

With reference to FIGS. 43-47, the first and second drive transferassemblies 568, 570 of the sterile interface module 530 includerespective drive couplers 568 a, 570 a defining coupling ends 568 b, 570b engagable with coupling ends 56 of respective motor couplers 52 b, 54b of the motor assembly 50. The first drive transfer assembly 568includes a transfer shaft 568 c and the second drive transfer assembly570 includes a transfer shaft 570 c. The transfer shafts 568 c, 570 c ofthe respective first and second drive transfer assemblies 568, 570extend to a respective instrument engagement end or coupler 568 e, 570 e(e.g., a gear or the like with distally extending teeth) at a distal endthereof.

It is contemplated that the transfer shaft 568 c of the first drivetransfer assembly 568 may further support a drive coupler 568 d thereonthat is disposed proximal of the instrument engagement coupler 568 e ofthe transfer shaft 568 c.

A respective biasing member or spring 568 f (the biasing member of thesecond drive transfer assembly 570 not being shown) is supported betweenthe drive couplers 568 a, 570 a and the transfer shafts 568 c, 570 c ofeach of the respective first and second drive transfer assemblies 568,570 such that each spring 568 f is configured to apply spring force toits respective first or second drive transfer assembly 568, 570 uponcompression thereof. The biasing members of the drive transferassemblies 568, 570 may be compression springs. The drive couplers 568a, 570 a of the first and second drive transfer assemblies 568, 570define side slots 568 g, 570 g therein that slidably receive wings 568 h(the wings of the second drive transfer assembly 570 not being shown)extending from the transfer shafts 568 c, 570 c of the first and seconddrive transfer assemblies 568, 570. The wings 568 h of the transfershafts 568 c, 570 c are configured to slide through the side slots 568g, 570 g of the first and second drive transfer assemblies 568, 570 inresponse to relative movement between one of the transfer shafts 568 c,570 c and its respective drive coupler 568 a, 570 a. In this regard, thedrive couplers 568 a, 570 a of the drive transfer assemblies 568, 570provide coupling in the manner of an “oldham” coupling. For example, theside slot 568 g of drive coupler 568 a is transverse and/orperpendicular to a slot defined by coupling end 568 b of drive coupler568 a, whereby the drive coupler 568 a couples transfer shaft 568 c ofdrive transfer assembly 568 and drive shaft 52 a of motor 52 via an“Oldham” coupling. In some embodiments, one or more mating surfaces ofany of the presently disclosed couplers, such as defined by coupling end568 b, for example, may include a slight draft angle to minimizebacklash (e.g., the spring 568 f pushes drive coupler 568 a toward driveshaft 52 a and the draft angle ensures that drive coupler 568 a anddrive shaft 52 a are bottomed out or in close approximation).

The sterile interface module 530 further includes a ring coupler or gear572 supported on an inner surface of the rotatable collar 564 of thesterile interface module 530. The sterile interface module 530 includesan idler coupler or gear 574 supported on the intermediate portion 562 bof the body member 562 of the sterile interface module 530. The idlergear 574 is enmeshed with a drive coupler or gear 568 d of the firstdrive transfer assembly 568 and selectively engagable with the ring gear572 (see FIGS. 43 and 44) in response to rotational movement of therotatable collar 564. The sterile interface module 530 further includessupport plates 576, 578 that are configured to laterally support thefirst and second drive transfer assemblies 568, 570. The support plate576 of the sterile interface module 530 is secured within a supportchannel 564 c (see FIG. 44) defined between the ring gear 572 and innersurfaces of the rotatable collar 564 such that the rotatable collar 564can rotate about the support plate 576 while axially moving the supportplate 576 relative to the transfer shafts 568 c, 570 a of first andsecond drive transfer assemblies 568, 570.

The support plate 576 can be secured to the drive couplers 568 a, 570 aof the first and second drive transfer assemblies 568, 570 to move thedrive couplers 568 a, 570 a axially relative to the transfer shafts 568c, 570 c of first and second drive transfer assemblies 568, 570 as thesupport plate 576 moves axially with the rotatable collar 564 of thesterile interface module 530. Axial movement of the drive couplers 568a, 570 a enables the driver couplers 568 a, 570 a to selectively engageand disengage the driver couplers 568 a, 570 a to/from the motorcouplers 54 b, 52 b of the motor assembly 50 of the housing 510 as therotatable collar 564 of the sterile interface module 530 moves betweenfirst and second positions (and any number of intermediate positionsbetween the first and second positions). The motor couplers 52 b, 54 bof the motor assembly 50 are engaged with the respective drive couplers568 a, 570 a of the sterile interface module 530 while the rotatablecollar 564 of the sterile interface module 530 is in the second position(FIGS. 42 and 44), and disengaged while the rotatable collar 564 of thesterile interface module 530 is in the first position (FIGS. 41 and 43).Advantageously, if the motor assembly 50 seizes, disengagement betweenthe motor couplers 52 b, 54 b of the motor assembly 50 and the drivecouplers 568 a, 570 a of the sterile interface module 530 provides asimplified separation of the sterile interface module 530 from the motorassembly 50 for an emergency release.

To couple an electromechanical surgical instrument such aselectromechanical surgical instruments 200, 250 etc. to the sterileinterface module 530, the ramped camming surfaces of the electrosurgicalinstrument (e.g., the ramped camming surfaces 218 of the housing 212 ofthe electromechanical surgical instrument 200) are aligned with thecorresponding ramp surfaces 562 x of the lower portion 562 c of thesterile interface module 530. The electromechanical surgical instrument200 is then transversely moved (e.g., side loaded) relative to therobotic surgical assembly 500 until the ramped camming surfaces of theelectromechanical surgical instrument are fully received or seated onramp surfaces 562 x of the lower portion 562 c of the sterile interfacemodule 530 similar to that described above with respect to coupling cuff176.

As the electromechanical surgical instrument is transversely moved intothe lower portion 562 c, the electromechanical surgical instrument camsupwardly (proximally, similar to that described above with respect tocoupling cuff 176) to proximally move or compress the floating plate566. Movement of the floating plate 566 into the compressed positiondraws the transfer shafts 568 c, 570 c (and their correspondinginstrument engagement ends 568 e, 570 e) proximally away from theinstrument opening 562 i of lower portion 562 c of the sterile interfacemodule 530 to facilitate insertion of the electromechanical surgicalinstrument 250 into the instrument opening 562 i of the sterileinterface module 530. Moving the floating plate 566 to the compressedposition helps prevent insertion contact/interference between theinstrument engagement ends 568 e, 570 e of the first and second drivetransfer assemblies 568, 570 of the sterile interface module 530 andcorresponding couplers of the electromechanical surgical instrument(e.g., the first and second drive assemblies 256 a-256 d ofelectromechanical surgical instrument 250 or the proximal couplers 310of electromechanical surgical instrument 200).

Once the electromechanical surgical instrument, such as electrosurgicalinstrument 250, is fully seated within the lower portion 562 c of thesterile interface module 530, the floating plate 566 is urged back tothe extended position thereof so that the instrument engagement ends 568e, 570 e of the first and second drive transfer assemblies 568, 570 ofthe sterile interface module 530 and corresponding couplers of the firstand second drive assemblies 256 a-256 d of the electromechanicalsurgical instrument 250 come into registration with one another tocouple the electromechanical surgical instrument 250 to the roboticsurgical assembly 500 via the sterile interface module 530.

In use, with the robotic surgical assembly 500 secured to one of thesurgical robotic arms 2, 3 and any electromechanical surgical instrument200, 200′, 200″ secured to the robotic surgical assembly 500, aclinician can perform a surgical procedure by robotically controlling,e.g., the electromechanical surgical instrument 250, with the roboticsurgical assembly 500 as desired. In particular, with rotatable collar564 of the sterile interface module 530 positioned in the secondposition to engage the motor and drive couplers 52 b, 54 b, 568 a, 570 aof the housing 510 and the sterile interface module 530, respectively,one or more of the motors 52, 54 of the motor assembly 50 are actuatedto rotate one or more of the motor couplers 52 b, 54 b of the motors 52,54 so that one or more of the first and second drive transfer assemblies568, 570 of the sterile interface module 530 cooperate with one or moreof the first and second drive assemblies 256 a-256 d of theelectromechanical surgical instrument 250 to operate and/or manipulatethe end effector 252 thereof as described herein.

With reference to FIGS. 42-44, in an emergency situation, while therotatable collar 564 of the sterile interface module 530 is in thesecond position at the second height “H2” with the shoulders 562 e, 564b of the upper portion 562 a of the body member 562 and of the rotatablecollar 562 engaged, the rotatable collar 564 can be rotated about thebody member 562, as indicated by arrow “B,” to move the rotatable collar564 axially in the distal direction toward the flange 562 h of theintermediate portion 562 b of the body member 562 of the sterileinterface module 530. In the second position of the rotatable collar564, the ring gear 572 is longitudinally spaced from the idler gear 574.

As described above, the rotatable collar 564 of the sterile interfacemodule 530 can be moved from the second position to the first position(any number of intermediate positions). For example, should a clinicianneed to manually control the end effector 252 of the electromechanicalsurgical instrument 250, for instance, during a power failure, aclinician can rotate the rotatable collar 564 of the sterile interfacemodule 530 relative to the body member 562 of the sterile interfacemodule 530 between the first and second positions (and any number ofintermediate positions between the first and second positions) to movethe rotatable collar 564 between first and second heights “H1” and “H2”relative to the flange 562 h of the intermediate portion 562 b of thebody member 562 of the sterile interface module 530.

Once the rotatable collar 564 of the sterile interface module 530 isrotated (from the second position toward the first position) through apredetermined angular rotation (e.g., 90 degrees, although the sterileinterface module 530, and/or one or more components thereof, can haveany suitable configuration to create the desired predetermined angularrotation), the ring gear 572 of the sterile interface module 530 engagesthe idler gear 574 of the sterile interface module 530 to effectuaterotation of the idler gear 574 as the ring gear 572 rotates and axiallyadvances distally toward the idler gear 574. Rotation of the idler gear574 rotates the drive gear 568 d of the first drive transfer assembly568 of the sterile interface module 530 independent of the second drivetransfer assemblies 570 of the sterile interface module 530 (whichgenerally remain stationary without robotic control thereof). As thedrive gear 568 d of the first drive transfer assembly 568 rotates inresponse to rotation of the idler gear 574 of the sterile interfacemodule 530, the first drive transfer assembly 568 of the sterileinterface module 530 cooperates with the first drive assembly 256 a ofthe electromechanical surgical instrument 250 to advantageously manuallymanipulate the end effector 252 thereof (e.g., to move one jaw thereofto open end effector 252 and release tissue grasped therein). It is alsocontemplated that the rotatable collar 564 of the sterile interfacemodule 530 can be rotated in the opposite direction as desired tomanipulate (e.g., close) the end effector 252 of the electromechanicalsurgical instrument 250.

The manual rotation of the rotatable collar 564 from the second positionto the first position (and/or from the first position to the secondposition), imparts forces through the respective components of thesterile interface module 530 and the electromechanical surgicalinstrument 250 to manually manipulate the end effector 252 of theelectromechanical surgical instrument 250 to position the end effector252 in a desired orientation/position. For example, the end effector 252of the electromechanical surgical instrument 250 can be manuallymanipulated to an open position to release tissue grasped by the endeffector 252 so that the electromechanical surgical instrument 250 canbe removed from a surgical site while limiting the risks of undesirabletissue damage that would otherwise be present if such manualmanipulation were not feasible when a power failure or other similaremergency situation arises.

To remove the electromechanical surgical instrument 250 from the roboticsurgical assembly 500, for example, to perform an instrument exchange(e.g., with one of electromechanical surgical instruments 200, 250′, or250″), a clinician can depress the paddles 254 a, 254 b of thedetachment assembly 254. Depression of the paddles 254 a, 254 b impartsa force on the tabs 566 b, 566 c of the floating plate 566 of thesterile interface module 530 to move the floating plate 566 in aproximal direction relative to the body member 562 of the sterileinterface module 530. As the floating plate 566 moves in a proximaldirection, the transfer shafts 568 c, 570 c of the first and seconddrive transfer assemblies 568, 570 translate with the floating plate 566in the proximal direction against biasing forces from the springs 568 f,570 f of the first and second drive transfer assemblies 568, 570.Movement of the transfer shafts 568 c, 570 c of the first and seconddrive transfer assemblies 568, 570 relative to the body member 562 ofthe sterile interface module 530 separates the instrument engagementends 568 e, 570 e of the transfer shafts 568 c, 570 c of the first andsecond drive transfer assemblies 568, 570 from the engagement couplers258 of the respective first and second drive assemblies 256 a-256 d ofthe electromechanical surgical instrument 250. Once the instrumentengagement ends or gears or couplers 568 e, 570 e of the transfer shafts568 c, 570 c of the first and second drive transfer assemblies 568, 570are separated from the engagement couplers 258 of the respective firstand second drive assemblies 256 a-256 d of the electromechanicalsurgical instrument 250, the proximal end of the instrument housing 253of the electromechanical surgical instrument 250 can be slid laterallyout from the instrument opening 562 i of the lower portion 562 c of thebody member 562.

The electromechanical surgical instrument 250 can be re-attached throughthe instrument opening 562 i of the lower portion 562 c of the bodymember 562 as described above. Alternatively, a differentelectromechanical surgical instrument such as the instrument 200, theendoscope 250,′ or the grasper 250″ can be likewise attached as desired.

Turning now to FIGS. 48-58, a robotic surgical assembly, according toanother embodiment of the present disclosure, is generally designated as600. The robotic surgical assembly 600 is similar to the roboticsurgical assembly 500 and thus will only be described in further detailherein to the extent necessary to describe differences in constructionand use therebetween. The robotic surgical assembly 600 of the roboticsurgical system 1 includes an instrument drive unit or housing 610supporting a motor assembly or motor pack 650 (FIG. 58). The housing 610of the robotic surgical assembly 600 includes a connector assembly 640.

Ring member 550 is configured for rotatable attachment to a distal endof the connector assembly 640 (e.g., via snap fit). The sterile drape552 can be arranged as desired about the housing 610, the roboticsurgical assembly 600 and the robotic arms 2, 3 to provide a sterilebarrier between the various aforementioned components and/or thesurgical site/fluids and the electromechanical surgical instruments 200(FIG. 2), 250, 250′, or 250″.

A collar assembly or sterile interface module 630 is provided forselectively interconnecting robotic surgical assembly 600 and any one ofthe electromechanical surgical instruments 200, 250, 250′, or 250″.

As seen in FIGS. 49-53, the collar assembly or sterile interface module630 includes electrical connectors 632 a, 632 b and an electrical ribbon(not shown) coupled between the electrical connectors 632 a, 632 b toprovide electrical communication between the robotic surgical assembly600 and any electromechanical surgical instrument, such aselectromechanical surgical instrument 250, coupled thereto. Theelectrical connectors 632 a, 632 b can be coupled to the sterileinterface module 630 by fasteners 697.

With reference to FIGS. 49-56, the sterile interface module 630 includesa body member 662 having an upper portion 662 a, an intermediate portion662 b secured to upper portion 662 a by fasteners 698, and a lowerportion 662 c secured to intermediate portion 662 b by fasteners 699.The upper portion 662 a of the body member 662 defines a helical channel662 d that extends around the upper portion 662 a from a shoulder 662 eof the upper portion 662 a. The upper portion 662 a further includes apair of attachment arms 662 f, 662 g that extend proximally from theupper portion 662 a to secure the sterile interface module 630 to theconnector assembly 640 of the housing 610 of the robotic surgicalassembly 600. The pair of attachment arms 662 f, 662 g may be disposedin mirrored relation on opposed sides of the upper portion 662 a.

With reference to FIGS. 49-51, the intermediate portion 662 b of thebody member 662 includes a flange 662 h and rotatably supports arotatable collar 664 thereon. The intermediate portion 662 b definesspaced apart openings 662 m in a side surface thereof. A safety clip 663may snap-fit into clip-receiving recesses 662 m of intermediate portion662 b of body member 162 to secure safety clip 663 onto sterileinterface module 630 at a location between rotatable collar 664 andflange 662 h of intermediate portion 662 b of body member 662. Thesafety clip 663 may take the form of a semi-circular cuff extendinggreater than 180° and be formed of a resilient material. The safety clip163 acts like a block or stopper to prevent approximation of rotatablecollar 664 toward flange 662 h of intermediate portion 662 b of bodymember 662, to thereby inhibit inadvertent approximation of rotatablecollar 664 toward flange 662 h of intermediate portion 662 b. Prior toactuation of rotatable collar 664, as described above, the safety clip663 must first be removed from between rotatable collar 664 and flange662 h of intermediate portion 662 b. The safety clip 663 may includenubs or the like 663 a extending radially inward therefrom and which areconfigured for receipt or disposition within openings 662 m formedwithin intermediate portion 662 b of body member 662.

The rotatable collar 664 of the sterile interface module 630 defines ahelical channel 664 a that extends from a shoulder 664 b of therotatable collar 664. The helical channel 664 a of the rotatable collar664 and the shoulder 664 b of the rotatable collar 664 complement thehelical channel 662 d of the upper portion 662 a of the body member 662and the shoulder 662 e of the upper portion 662 a of the body member662. The rotatable collar 664 further includes gripping grooves 664 c tofacilitate user gripping and/or actuation of the rotatable collar 664relative to the body member 662 of the sterile interface module 630. Therotatable collar 664 also includes a lip 664 d that extends distallyfrom the rotatable collar 664 and is engagable with the safety clip 663to enable the safety clip to prevent movement of the rotatable collar664 toward the flange 662 h of the intermediate portion 662 b asdiscussed above. The rotatable collar 664 may also include indicia 664 ethereon or defined therein (e.g., one or more arrows) to provideinformation to a clinician. In some embodiments, the indicia may provideoperation instruction.

The lower portion 662 c of the body member 662 of the sterile interfacemodule 630 is in the form of a semi-annular coupling cuff that issecured to a distal end of the intermediate portion 662 b of the bodymember 662 via fasteners 699. The lower portion 662 c of the body member662 includes a U-shaped body having an instrument opening 662 i definedbetween side arms 662 j, 662 k and opening distally and laterally. Thelower portion 662 c further includes a ramp surface 662 x (FIG. 49) thatcomplements the ramped camming surfaces of the housing of theelectromechanical surgical instruments (e.g., ramped camming surfaces218 of the housing 212 of the electromechanical surgical instrument200). The instrument opening 662 i is configured to receive anelectromechanical surgical instrument, such as electromechanicalsurgical instrument 250, therein to removably secure theelectromechanical surgical instrument 250 to the robotic surgicalassembly 600. The side arms 662 j, 662 k of the lower portion 662 cextend distally from the intermediate portion 662 b of the body member662 and are positioned to support the electromechanical surgicalinstrument 250 within the instrument opening 662 i of the lower portion662 c when the electromechanical surgical instrument 250 is receivedtherein (e.g., via side loading).

Similar to the floating plate 566 of the sterile interface module 530,the sterile interface module 630 further includes a floating plate 666supported between the intermediate portion 662 b of the body member 662and the lower portion 662 c of the body member 662. The floating plate666 is movable between an uncompressed position or extended position anda compressed or retracted position. The floating plate 666 is springbiased distally toward the uncompressed position by springs 665 adisposed between the floating plate 666 and the intermediate portion 662b of the body member 662 and by springs of drive transfer assemblies(e.g., 668, 670) of the sterile interface module 630. In theuncompressed position of the lower floating plate 666, the floatingplate 666 is spaced a distance “E” (see FIG. 55) from a bottom surface662 e of the intermediate portion 662 b. The floating plate 666 includesa base portion 666 a and tabs 666 b, 666 c that extend distally from thebase portion 666 a. The tabs 666 b, 666 c extend through the lowerportion 662 c of the body member 662. The floating plate 666 definesapertures 666 d, 666 e therein that receive first and second drivetransfer assemblies 668, 670 of the sterile interface module 630.

With reference to FIGS. 49-52 and 58, the first and second drivetransfer assemblies 668, 670 of the sterile interface module 630 includerespective drive couplers 668 a, 670 a defining coupling ends 668 b, 670b engagable with coupling ends 626 of respective motor couplers 652 a,654 a of the motor assembly 650 supported within the housing 610. Thefirst drive transfer assembly 668 includes a transfer shaft 668 c andthe second drive transfer assembly 670 includes a transfer shaft 670 c.The transfer shafts 668 c, 670 c of the respective first and seconddrive transfer assemblies 668, 670 extend to a respective instrumentengagement end or 668 e, 670 e (e.g., a gear or the like with distallyextending teeth) at a distal end thereof. The transfer shaft 668 c ofthe first drive transfer assembly 668 further includes a drive coupleror gear 668 d supported proximal to instrument engagement end 668 e oftransfer shaft 668 c.

Respective biasing members or springs 668 f, 670 f are supported betweenthe drive couplers 668 a, 670 a and the transfer shafts 668 c, 670 c ofeach of the respective first and second drive transfer assemblies 668,670 such that each spring 668 f, 670 f is configured to apply springforce to its respective first or second drive transfer assembly 668, 670upon compression thereof. The biasing members 668 f, 670 f of the drivetransfer assemblies 668, 670 may be compression springs. The drivecouplers 668 a, 670 a of the first and second drive transfer assemblies668, 670 define side slots 668 g, 670 g therein that slidably receivewings 668 h, 670 h extending from the transfer shafts 668 c, 670 c ofthe first and second drive transfer assemblies 668, 670. The wings 668h, 670 h of the transfer shafts 668 c, 670 c are configured to slidethrough the side slots 668 g, 670 g of the first and second drivetransfer assemblies 668, 670 in response to relative movement betweenone of the transfer shafts 668 c, 670 c and its respective drive coupler668 a, 670 a (e.g., in the manner of an “oldham” coupling).

The sterile interface module 630 further includes a ring coupler or gear672 supported on an inner surface of the rotatable collar 664 of thesterile interface module 630. The sterile interface module 630 includesan idler coupler or gear 674 supported by the intermediate portion 662 bof the body member 662 of the sterile interface module 630. The idlergear 674 is enmeshed with the drive gear 668 d of the first drivetransfer assembly 668 and selectively engagable with the ring gear 672(see FIGS. 55 and 56) in response to rotational movement of therotatable collar 664.

The sterile interface module 630 further includes support plates 676,678 that are configured to laterally support the first and second drivetransfer assemblies 668, 670. The support plate 676 is generallysupported between the upper portion 662 a of the body member 662 and theintermediate portion 662 b of the body member 662.

As seen in FIGS. 55 and 56, the support plate 676 of the sterileinterface module 630 is secured within a support channel 664 c definedbetween the ring gear 672 and inner surfaces of the rotatable collar 664such that the rotatable collar 664, with the safety clip 663 removed asdetailed herein, can rotate about the support plate 676 while axiallymoving the support plate 676 relative to the upper portion 662 a of thebody member 662 of the sterile interface module 630. The support plate676 is coupled to flanges 668 z, 670 z of the drive couplers 668 a, 670a of the first and second drive transfer assemblies 668, 670 to move thedrive couplers 668 a, 670 a axially relative to the transfer shafts 668c, 670 c of first and second drive transfer assemblies 668, 670 as thesupport plate 676 moves axially with the rotatable collar 664 of thesterile interface module 630. Axial movement of the drive couplers 668a, 670 a enables the driver couplers 668 a, 670 a to selectively engageand disengage the driver couplers 668 a, 670 a to/from the motorcouplers 652 a, 654 a (FIG. 58) of the motor assembly 50 of the housing610 as the rotatable collar 664 of the sterile interface module 630moves between first and second positions (and any number of intermediatepositions between the first and second positions). The motor couplers652 a, 654 a of the motor assembly 650 are engaged with the respectivedrive couplers 668 a, 670 a of the sterile interface module 630 whilethe rotatable collar 664 of the sterile interface module 630 is in thesecond position (FIGS. 55 and 58), and disengaged while the rotatablecollar 664 of the sterile interface module 630 is in the first position(FIG. 56).

To couple an electromechanical surgical instrument, such aselectromechanical surgical instrument 250, to sterile interface module630, the ramped camming surfaces of the housing of the electromechanicalsurgical instrument (see e.g., the ramped camming surfaces 218 of thehousing 212 of the electromechanical surgical instrument 200) arealigned with the corresponding ramp surfaces 662 x of the lower portion662 c of the sterile interface module 630. The electromechanicalsurgical instrument 250 is then transversely moved (e.g., side loaded)relative to robotic surgical assembly 600 until seated on ramp surfaces662 x of the lower portion 662 c of the sterile interface module 630similar as that described above with respect to coupling cuff 176 andthe sterile interface module 530.

As electromechanical surgical instrument 250 is transversely moved intothe lower portion 662 c, as described above, the floating plate 566 isurged toward the compressed position thereof against the spring bias ofthe first and second drive transfer assemblies 668, 670 and the springbias of the springs 665 that extend proximally from the floating plate666. Movement of the floating plate 666 into the compressed positiondraws the transfer shafts 668 c, 670 c (and their correspondinginstrument engagement ends 668 e, 670 e) proximally away from theinstrument opening 662 i of lower portion 662 c of the sterile interfacemodule 630 to facilitate insertion of the electromechanical surgicalinstrument 250 into the instrument opening 662 i of the sterileinterface module 630. Moving the floating plate 666 to the compressedposition helps prevent insertion contact/interference between theinstrument engagement ends 668 e, 670 e of the first and second drivetransfer assemblies 668, 670 and corresponding gears or couplers of thefirst and second drive assemblies 256 a-256 d of the electromechanicalsurgical instrument 250.

Once the electromechanical surgical instrument 250 is fully seatedwithin the lower portion 662 c of the sterile interface module 630, thefloating plate 666 is urged back to the extended position thereof inresponse to the spring bias of springs 665 and first and second drivetransfer assemblies 668, 670 so that the instrument engagement ends 668e, 670 e of the first and second drive transfer assemblies 668, 670 ofthe sterile interface module 630 and corresponding gears or couplers ofthe first and second drive assemblies 256 a-256 d of theelectromechanical surgical instrument 250 come into registration withone another to couple the electromechanical surgical instrument 250 tothe robotic surgical assembly 600 via the sterile interface module 630.

In use, with the robotic surgical assembly 600 secured to one of thesurgical robotic arms 2, 3 and any electromechanical surgical instrument200, 250, 250′, 250″ secured to the robotic surgical assembly 600, aclinician can perform a surgical procedure by robotically controlling,e.g., the electromechanical surgical instrument 250 with the roboticsurgical assembly 600 as desired. In particular, with rotatable collar664 of the sterile interface module 630 positioned in the secondposition, the motor assembly 50 can be actuated to so that one or moreof the first and second drive transfer assemblies 668, 670 of thesterile interface module 530 cooperate with one or more of the first andsecond drive assemblies 256 a-256 d of the electromechanical surgicalinstrument 250, for example, to operate and/or manipulate the endeffector 252 thereof as described herein similar to that described abovewith respect to robotic surgical assembly 500.

With reference to FIGS. 51, 54-56, and 58, in an emergency situation(e.g. a power failure), the safety clip 663 is manually removed from thesterile interface module 630 while the rotatable collar 664 of thesterile interface module 630 is in the second position with the ringgear 672 longitudinally spaced from the idler gear 674. Once the safetyclip 663 is removed, the rotatable collar 664 can be manually rotatedabout the body member 662, as indicated by arrow “F” (FIG. 54), to movethe rotatable collar 664 axially in the distal direction toward theflange 662 h of the intermediate portion 662 b of the body member 662 ofthe sterile interface module 630 to separate the drive couplers 668 a,670 a of the first and second drive transfer assemblies 668, 670 fromthe motor couplers 652 a, 654 a of the motor assembly 650 of the housing610 similar to that described above with respect to sterile interfacemodule 530.

Further, similar to sterile interface module 530, the rotatable collar664 of the sterile interface module 630 can be rotated from the secondposition toward the first position through a predetermined angularrotation. With the ring gear 672 coupled to the rotatable collar 664,such rotation enables the ring gear 672 of the sterile interface module630 to engage the idler gear 674 of the sterile interface module 630 tocause rotation of the idler gear 674 as the ring gear 672 rotates andaxially advances distally toward the idler gear 674. Rotation of theidler gear 674 rotates the drive gear 668 d of the first drive transferassembly 668 of the sterile interface module 630 independent of thesecond drive transfer assemblies 670 of the sterile interface module 630(which generally remain stationary without robotic control thereof).

As the drive gear 668 d of the first drive transfer assembly 668 rotatesin response to rotation of the idler gear 674 of the sterile interfacemodule 630, the first drive transfer assembly 668 of the sterileinterface module 630 cooperates with the first drive assembly 256 a ofthe electromechanical surgical instrument 250 to advantageously manuallymanipulate the end effector 252 thereof similar to that described abovewith respect to sterile interface module 530.

To remove the electromechanical surgical instrument 250 from the roboticsurgical assembly 600, for example, to perform an instrument exchange(e.g., with one of electromechanical surgical instruments 200, 250′ or250″), a clinician can depress the paddles 254 a, 254 b of thedetachment assembly 254 of the electromechanical surgical instrument 250to release the electromechanical surgical instrument 250 from therobotic surgical assembly 600 similar to that described above withrespect to robotic surgical assembly 500. In particular, depressing thepaddles 254 a, 254 b of the detachment assembly 254 of theelectromechanical surgical instrument 250 moves the floating plate 666to move to the compressed position against the bias of the springs ofthe sterile interface module 630 to enable the electromechanicalsurgical instrument 250 to be slid laterally out from the instrumentopening 662 i of the lower portion 662 c of the body member 662 thereofsimilar to that described above with respect to sterile interface module530.

The electromechanical surgical instrument 250 can be re-attached throughthe instrument opening 662 i of the lower portion 662 c of the bodymember 662 as desired or needed. Alternatively, a differentelectromechanical surgical instrument such as the instrument 200, theendoscope 250′ or the grasper 250″ can be likewise attached as desiredor needed.

The drive members 380 and/or the connector members “CM” (see FIGS. 15and 36) of some embodiments of the electromechanical surgicalinstruments may include any suitable material such as stainless steel,tungsten, polymer or the like. Such material may include one or morecoatings, which may include one or more layers. These coatings mayinclude polymeric material such as any suitable poly(p-xylylene) polymer(e.g., parylene or the like). Any of these polymeric materials can beformed by any suitable technique such as chemical vapor deposition orthe like. Such coatings are configured to increase reliability and/orthe life-cycle of the drive members 380 and/or the connector members“CM.” Advantageously, poly(p-xylylene) polymers such as parylene arebio-compatible and provide low-friction and lubricity for application toalmost any surface (e.g., a cable). For example, the presently describedelectromechanical surgical instruments may include drive or connectingmembers formed of tungsten cables coated with a poly(p-xylylene)polymers such as parylene in order to provide longer instrument life. Inaddition, such poly(p-xylylene) polymers provide a dielectric barrier.The poly(p-xylylene) polymer coating protects the tungsten cables (andany internal lubricants of the tungsten cables) from washing and/orautoclaving procedures. In addition, the poly(p-xylylene) polymercoating provides a layer of protection between the tungsten cables andthe pulleys on which the tungsten cables ride. In certain embodiments,the one or more coatings may include polytetrafluoroethylene (e.g.,Teflon) or the like material.

Any of the presently described sterile interface modules, or portionsthereof, can be formed of dielectric material (e.g., any suitablepolymer) and/or function as a dielectric to prevent current leakage. Forexample, one suitable polymer may include Polyphenylsulfone (e.g.,Radel® R-5100) or the like. In some embodiments, the presently describedsterile interface modules are configured to electrically isolatededicated electrocautery cables, such as electrosurgical cable 599 (seeFIG. 45) or the like from other electrical components such as those usedfor information transmission (e.g., electrical connectors 532 a, 632 a,electrical ribbon 534, etc.) Further, the electrosurgical cable and/orany electrical component, such as electrical connectors 532 a, can bepositioned as predetermined spaced locations relative to one another,whereby predetermined distance between such components can act as adielectric.

In some embodiments, the presently described sterile interface modules,or portions thereof, may be autoclavable.

With reference to FIG. 59, one embodiment of a robotic surgical systemincludes a robotic surgical assembly 1100 coupled with or to one of therobotic arms 2 or 3 (see FIG. 1). The robotic surgical assembly 1100includes a surgical instrument holder 1102, an instrument drive unit1110, and an electromechanical surgical instrument such aselectromechanical surgical instrument 1200. The instrument drive unit1110 transfers power and actuation forces from its motors to drivenmembers (not shown) of the electromechanical surgical instrument 1200 toultimately drive movement of components of an end effector 1210 of theelectromechanical surgical instrument 1200, for example, a movement of aknife blade (not shown) and/or a closing and opening of jaw members ofthe end effector 1210, the actuation or firing of a stapler, and/or theactivation or firing of an electrosurgical energy-based instrument, orthe like. A motor assembly 1114 (FIGS. 67 and 68) of the instrumentdrive unit 1110 is rotated by motor “M” supported in the surgicalinstrument holder 1102 and transfers its rotational motion to theelectromechanical surgical instrument 1200.

With reference to FIGS. 59, 60A, 60B, and 61, the surgical instrumentholder 1102 of the surgical assembly 1100 functions to actuate arotation of the motor assembly 1114 (FIG. 68) of the instrument driveunit 1110. The surgical instrument holder 1102 includes a back member orcarriage 1104, and an outer member or housing 1106 extending laterally(e.g., perpendicularly) from an end 1104 b of a carriage 1104. In someembodiments, the housing 106 may extend at various angles relative tothe carriage 1104 and from various portions of the carriage 1104. Thecarriage 1104 has a first side 1108 a and a second side 1108 b, oppositeto the first side 1108 a. The first side 1108 a of the carriage 1104 isdetachably connectable to the rail 40 of the robotic arm 2 to enable thesurgical instrument holder 1102 to slide or translate along the rail 40of the robotic arm 2 (see FIG. 1). The second side 1108 b of thecarriage 1104 is configured to non-rotatably support a housing or outershell 1112 of the instrument drive unit 1110.

The carriage 1104 of the surgical instrument holder 1102 supports orhouses a motor, such as, for example, a canister motor “M” therein. Themotor “M” receives controls and power from the control device 4 (FIG. 1)to ultimately rotate the motor assembly 1114 of the instrument driveunit 1110, as will be described in detail below. In some embodiments,the carriage 1104 may include a printed circuit board 1107 in electricalcommunication with the motor “M” to control an operation of the motor“M” of the carriage 1104. The carriage 1104 has a rotatable drive shaft1109 extending from the motor “M” and longitudinally through thecarriage 1104. The carriage 1104 further includes a shaft coupling 1116non-rotatably connected to a drive shaft 1109 of the motor “M” totransfer rotation of the drive shaft 1109 of the motor “M” to a pulley1154 of a drive assembly 1150 of the surgical instrument holder 1102.

With reference to FIGS. 60A-64B, the housing 1106 of the surgicalinstrument holder 1102 defines a channel 1118 therethrough configured torotatably receive and support the instrument drive unit 1110 therein.The housing 1106 has a generally oblong semicircular shape, but in someembodiments, the housing 1106 may assume a variety of shapes, such as,for example, C-shaped, U-shaped, V-shaped, hook-shaped, or the like. Thehousing 1106 of the surgical instrument holder 1102 is furtherconfigured to house or retain the components of the drive assembly 1150,which will be described in detail below.

With specific reference to FIGS. 62, 63, 64A, and 64B, the housing 1106of the surgical instrument holder 1102 generally includes a sidewall1120 defining an enclosure 1122 therein, and a top plate 1124 connectedto a top portion of the sidewall 1120. The sidewall 1120 has a firstportion 1120 a having a semicircular configuration and a second portion1120 b having a square or rectangular configuration. The first portion1120 a of the sidewall 1120 has a top ridge or ledge 1126 a extendinginwardly into the enclosure 1122 from the top portion of the sidewall1120. The top ledge 1126 a defines a cutout 1128 a therein configuredfor receipt of a portion of a first bearing 1153 a of the drive assembly1150. The first bearing 1153 a has an inner diameter of approximately50-70 millimeters, for example, about 60 millimeters, an outer diameterof approximately 50-70 millimeters, for example, about 66 millimeters, awidth of approximately 1-4 millimeters, for example, about 2.5millimeters, and a mass of approximately 5-15 grams, for example, about9 grams. The housing 1106 further includes a base 1130 disposed withinthe enclosure 1122.

The base 1130 is connected to a bottom portion of the sidewall 1120. Thebase 1130 includes a circular inner surface 1132 that defines thecircular channel 1118 therethrough. The circular channel 1118 isconfigured for receipt of an annular member 1182 of the drive assembly1150. The base 1130 further includes a bottom ridge or ledge 1126 bextending inwardly into the central channel 1118 from the inner surface1132 of the base 1130. The bottom ledge 1126 b defines a cutout 1128 btherein configured for receipt of a second bearing 1153 b of the driveassembly 1150, similar to the first bearing 1153 a described above. Thetop and bottom ledges 1126 a, 1126 b of the housing 1106 cooperativelydefine a groove 1134 therebetween configured for slidable receipt of abelt 1160 of the drive assembly 1150.

The housing 1106 further includes a curved or arcuate wall 1136extending upwardly from base 1130, and is disposed adjacent the secondportion 1120 b of the sidewall 1120, partially surrounding the centralchannel 1118. The arcuate wall 1136 of the housing 1106 has a top ridgeor ledge 1138 extending into the enclosure 122 and outwardly from aninner surface 1140 of the arcuate wall 1136. The top ledge 1138 of thearcuate wall 1136 is coplanar with the top ledge 1126 a of the firstportion 1120 a of the sidewall 1120 such that the top ledges 1126 a,1138 provide clearance for a pre-loaded spring (e.g., wave spring).

With reference to FIGS. 61-66, the drive assembly 1150 of the surgicalinstrument holder 1102 is configured to transfer a rotation of the driveshaft 1109 of the motor “M” of the surgical instrument holder 1102 intorotational motion of the motor assembly 1114 (FIG. 68) of the instrumentdrive unit 1110 when the instrument drive unit 1110 is operably receivedwithin the surgical instrument holder 1102. The drive assembly 1150includes a driven shaft 1152 rotatably disposed within the housing 1106.The driven shaft 1152 has a proximal end 1152 a, and a distal end 1152b. The proximal end 1152 a of the driven shaft 1152 extends proximallythrough the top plate 1124 of the housing 1106. The distal end 1152 b ofthe driven shaft 1152 extends distally through the base 1130 of thehousing 1106. The driven shaft 1152 of the drive assembly 1150 isrotatably retained within the housing 1106.

As illustrated in FIG. 61, the motor “M” of the carriage 1104, the driveshaft 1109 of the carriage 1104, and the driven shaft 1152 of the driveassembly 1150 are each in line with one another. The proximal end 1152 aof the driven shaft 1152 is non-rotatably connected to a shaft coupling1116 of the carriage 1104 such that rotation of the drive shaft 1109 ofthe motor “M” causes the shaft coupling 1116 to rotate and, in turn, thedriven shaft 1152 of the drive assembly 1150 to rotate.

With continued reference to FIGS. 61-66, the drive assembly 1150includes a first pulley 1154 and a second pulley 1156; each disposedwithin a space 1142 defined between the arcuate wall 1136 of the housing1106 and the sidewall 1120 of the housing 1106, and specifically atrespective opposing corners 1144 a, 1144 b of the second portion 1120 bof the sidewall 1120. The distal end 1152 b of the driven shaft 1152 isnon-rotatably connected to the first pulley 1154 such that rotation ofthe driven shaft 1152 effects rotation of the first pulley 1154 relativeto the housing 1106. The first and second pulleys 1154, 1156 may beselectively movable within the housing 1106 to different locations ofthe housing 1106. The first and second pulleys 1154, 1156 may each be inthe form of gears, such as, for example, spur gears having teeth 1158extending radially from a periphery thereof. In some embodiments, thefirst and second pulleys 1156 may have smooth outer surfaces withoutteeth.

The drive assembly 1150 further includes a drive strap or belt 1160rotatably and/or translatably received within the housing 1106. The belt1160 is a closed loop and fabricated from a pliable material such thatthe belt 1160 may be manipulated into any suitable shape. In particular,the belt 1160 takes on the oblong semicircular shape of the housing 1106upon being received in the housing 1106. In some embodiments, the belt1160 may be formed from a rigid material and have a permanent oblongsemicircular shape corresponding to the shape of the enclosure 1122 ofthe housing 1106. The belt 1160 may have teeth 1162 extending from aninner surface thereof. The belt 1160 is wrapped around the first andsecond pulleys 1154, 1156 such that the teeth 1162 of the belt 1160 arein operable engagement with the teeth 1158 of the first and secondpulleys 1154, 1156. In this way, rotation of the first pulley 1154caused by actuation of the motor “M” of the carriage 1104, causes thebelt 1160 to rotate around the first and second pulleys 1154, 1156. Thesecond pulley 1156 acts as an idler pulley to guide the belt 1160 aroundthe inner periphery of the sidewall 1120 of the housing 1106. It iscontemplated that the second pulley 1156 may be selectively moved to aplurality of positions to effect the tension on/of the belt 1160.

With reference to FIG. 66A, in one embodiment, the drive assembly 150may include a tensioning assembly 1164 configured to adjust the tensionon/of the belt 1160. In particular, the tensioning assembly 1164 may beplaced within a space 1142 defined between the arcuate wall 1136 of thehousing 1106 and the sidewall 1120 of the housing 1106, and extendbetween the first and second pulleys 1154, 1156. The tensioning assembly1164 includes a first shaft assembly 1166, a second shaft assembly 1168,and a coil spring 1170.

The first shaft assembly 1166 is in a fixed position within the housing1106 and includes a block 1172 disposed adjacent the first pulley 1154,and a shaft 1174 extending from the block 1172 and along an axisintersecting the first and second pulleys 1154, 1156. The second shaftassembly 1168 includes a block 1176 disposed adjacent a pulley sled1180, and a tubular shaft 1178 extending from the block 1176. Withreference to FIG. 66B, the pulley sled 1180 rotatably supports thesecond pulley 1156 about a shaft 1181 and includes an engagement tab1180 a in contacting relation with the block 1176. The tubular shaft1178 of the second shaft assembly 1168 has shaft 1174 of the first shaftassembly 1166 extending therethrough and is slidable along the shaft1174 of the first shaft assembly 1166. The coil spring 1170 is disposedabout the tubular shaft 1178 and captured between the blocks 1172, 1176of respective first and second shaft assemblies 1166, 1168 toresiliently bias the block 1176 of the second shaft assembly 1168 awayfrom the block 1172 of the first shaft assembly 1166. The coil spring1170 pushes on the block 1176, which pushes on a pulley sled 1180 tobias the second pulley 1156 away from the first pulley 1154 and adjust(e.g., increase) tension in the belt 1160. The pulley sled 1180, and itscomponents, are slidable along the axis defined by the shaft 1174 inresponse to longitudinal translation of the block 1176 (e.g., to adjusttension in the belt 1160).

To adjust the amount of tension contributed by the tensioning assembly1164, a plurality of coil springs, each having different spring forces,may be interchanged for the coil spring 1170. Alternately, to adjust thetension in the belt 1160, the tensioning assembly 1164 may be moved todifferent positions relative to the second pulley 1156.

With continued reference to FIGS. 62, 64B, and 65B, the drive assembly1150 includes a cup-shaped annular member 1182 rotatably disposed withinthe channel 1118 of the housing 106 between the first and secondbearings 1153 a, 1153 b of the drive assembly 1150. The annular member1182 includes a ring 1184, and an annular base plate or disc 1186disposed within the ring 1184. The ring 184 has a plurality of teeth1188 extending radially from an outer surface thereof. With the annularmember 1182 rotatably seated between the first and second bearings 1153a, 1153 b of the drive assembly 1150, the teeth 1188 of the annularmember 1182 are in operable engagement with the teeth 1162 of the belt1160. In this regard, movement of the belt 1160 along the innerperiphery of the sidewall 120 of the housing 106 by rotation of thefirst pulley 154 causes the annular member 1182 to rotate within thechannel 1118 of the housing 1106.

In some embodiments, the first pulley 1154 and the belt 1160 do not haveteeth for transferring rotational motion between one another. Instead,rotation is transferred between the first pulley 1154 and the belt 1160via the frictional engagement of a smooth inner surface of the belt 1160with a smooth outer surface of the first pulley 1154. It is contemplatedthat each of the components of the drive assembly 1150 may be removablefrom the housing 1106 to facilitate assembly, repair, and adjustments ofthe drive assembly 1150.

With reference to FIGS. 64B, 65B, 67, and 68, the annular base plate1186 of the annular member 1182 and an inner surface 1190 of the ring1184 of the annular member 1182 cooperatively define a cylindricalcavity 1192 configured for receipt of the instrument drive unit 1110.The annular base plate 1186 defines a plurality of holes 1194therethrough configured for receipt of various drive shafts (not shown)of the instrument drive unit 1110. With the drive shafts of theinstrument drive unit 1110 extending through the holes 1194 of theannular base plate 1186, rotation of the annular member 1182 via belt1160 results in rotation of the motor assembly 1114 of the instrumentdrive unit 1110 relative to the housing 1106 of the surgical instrumentholder 1102, as will be described in detail below.

To assemble the drive assembly 1150, the belt 1160 is lowered into thehousing 1106 to line the inner periphery of the sidewall 1120 of thehousing 1106 and extend through the groove 1134 defined between theupper and lower ledges 1128 a, 1128 b of the housing 106. The firstbearing 1153 a is pressed onto an upper portion of the annular member1182 and the second bearing 1153 b is pressed onto a lower portion ofthe annular member 1182. The annular member 1182 with the first andsecond bearings 1153 a, 1153 b is lowered into the channel 1118 of thehousing 1106 and supported between the upper and lower ledges 1128 a,1128 b of the housing 1106. The first and second pulleys 1154, 1156 areinstalled in opposing corners 1144 a, 1144 b of the housing 1106 suchthat the belt 1160 wraps around the first and second pulleys 1154, 1156and around the annular member 1182. At this stage of assembly, the belt1160 may be tensioned. The cover plate 1124 is then secured to the topportion of the housing 1106.

With reference to FIGS. 67 and 68, the instrument drive unit 1110 of thesurgical assembly 1100 includes an outer housing 1112 and an innerhousing or motor assembly 1114 rotatably disposed within the outerhousing 1112. The outer housing 1112 is engaged to the second side 1108b of the carriage 1104 of the surgical instrument holder 1102 and housesvarious components of the instrument drive unit 1110. The outer housing1112 of the instrument drive unit 1110 has a generally cylindricalconfiguration, but in some embodiments, the outer housing 1112 mayassume a variety of configurations, such as, for example, squared,elongate, tubular, or the like.

The outer housing 1112 of the instrument drive unit 1110 is configuredand dimensioned to slidably receive a motor assembly, motor pack or thelike 1114 therein. The motor assembly 1114 may include four motors“M1-M4,” for example, canister motors or the like, each having a driveshaft (not explicitly shown) having a non-circular transversecross-sectional profile (e.g., substantially D-shaped, or the like). Thefour motors are arranged in a rectangular formation such that respectivedrive shafts thereof are all parallel to one another and all extendingin a common direction. As the motors of the motor assembly 1114 areactuated, rotation of the drive shafts of the motors is transferred togears (not shown) of drive assemblies (not shown) of the surgicalinstrument 1200 via respective drive transfer shafts (not shown) toactuate various functions of the surgical instrument 1200. In addition,as mentioned above, when the instrument drive unit 1110 is disposedwithin the annular member 1182 of the drive assembly 1150 of thesurgical instrument holder 1102, the drive shafts of each motor of themotor assembly 1114 extend through the holes 1194 of the annular baseplate 1186 of the annular member 1182.

In operation, the carriage 1104 of the surgical instrument holder 1102is attached to the rail 40 of the robotic arm 2. The instrument driveunit 1110 is positioned within the annular member 1182 of the driveassembly 1150 and supported on the side 1108 b of the carriage 1104 ofthe surgical instrument holder 1102 so that the drive shafts (not shown)of the motor assembly 1114 of the instrument drive unit 1110 extendthrough the respective holes 1194 defined in the annular base plate 1186of the annular member 1182. The driven shafts (not shown) of theproximal end 1202 (FIG. 59) of the surgical instrument 1200 arenon-rotatably connected to the drive shafts of the motor assembly 1114of the instrument drive unit 1110.

A clinician operating the manual input devices 7, 8 (FIG. 1) of thesurgical system may actuate the motor “M” of the surgical instrumentholder 1102 to ultimately effect rotation of the surgical instrument1200 to orient the surgical instrument 1200 in a particular positionwithin a surgical site. In particular, actuation of the motor “M” of thesurgical instrument holder 1102 drives rotation of the motor shaft 1109of the surgical instrument holder 1102, which transfers its rotationalmotion to the driven shaft 1152 of the drive assembly 150 via the shaftcoupling 1116. Rotation of the driven shaft 1152 of the drive assembly1150 effects rotation of the first pulley 1154 due to the first pulley1154 being non-rotatably connected to the driven shaft 1152. Since thebelt 160 of the drive assembly 1150 is in operable engagement with thefirst pulley 1154 of the drive assembly 1150, and the annular member1182 of the drive assembly 1150 is in operable engagement with the belt1160, rotation of the first pulley 1154 causes the belt 1160 of thedrive assembly 1150 to rotate and, in turn, causes the annular member1182 of the drive assembly 150 to rotate.

With the drive shafts of the motor assembly 1114 of the instrument driveunit 1110 captured in the holes 1194 of the annular base plate 1186 ofthe annular member 1182 of the drive assembly 1150, rotation of theannular member 1182 of the drive assembly 1150 within the housing 1106of the surgical instrument holder 1102 drives a rotation of the motorassembly 1114 of the instrument drive unit 1110 relative to the outershell 1112 of the instrument drive unit 1110. In some embodiments, themotor assembly 1114 of the instrument drive unit 1110 may benon-rotatably received within the annular member 1182 of the driveassembly 1150 via any suitable method, for example, friction fit,non-circular complimentary mating surfaces, or any suitable fastener. Incertain embodiments, the motor assembly 1114 is bolted to the annularmember 1182. With the proximal end 1202 of the surgical instrument 200non-rotatably coupled to the motor assembly 1114 of the instrument driveunit 1110, rotation of the motor assembly 1114 of the instrument driveunit 1110 results in rotation of the surgical instrument 200 about itslongitudinal axis “X.”

Persons skilled in the art will understand that the structures andmethods specifically described herein and shown in the accompanyingfigures are non-limiting exemplary embodiments, and that thedescription, disclosure, and figures should be construed merely asexemplary of particular embodiments. It is to be understood, therefore,that the present disclosure is not limited to the precise embodimentsdescribed, and that various other changes and modifications may beeffected by one skilled in the art without departing from the scope orspirit of the disclosure. Additionally, the elements and features shownor described in connection with certain embodiments may be combined withthe elements and features of certain other embodiments without departingfrom the scope of the present disclosure, and that such modificationsand variations are also included within the scope of the presentdisclosure. Accordingly, the subject matter of the present disclosure isnot limited by what has been particularly shown and described.

The invention claimed is:
 1. A robotic surgical system comprising: arobotic arm; a carriage coupled to the robotic arm and rotatablysupporting an instrument rotation pulley and a motor axis pulley; adrive belt coupled to the instrument rotation pulley and the motor axispulley; a motor supported by the carriage and including a coupling thatis driven by the motor upon an actuation of the motor, the couplingengaged with the motor axis pulley such that rotation of the motor axispulley rotates the drive belt to rotate the instrument rotation pulley;a surgical instrument configured to couple to the carriage; a sterilebarrier housing including a drive transfer assembly configured to coupleto the surgical instrument; and a sterile barrier collar assemblyconfigured to couple to the drive transfer assembly, the sterile barriercollar assembly configured to support the surgical instrument while thesurgical instrument is coupled to the drive transfer assembly, whereinthe drive transfer assembly and the sterile barrier collar assemblyrotate together in response to rotation of the instrument rotationpulley so that the surgical instrument rotates along a longitudinal axisthereof while coupled to the sterile barrier collar assembly.
 2. Therobotic surgical system of claim 1, wherein the surgical instrumentoperably couples to the instrument rotation pulley such that rotation ofthe instrument rotation pulley rotates the surgical instrument.
 3. Therobotic surgical system of claim 1, wherein the sterile barrier housingincludes a cap, the cap removable to expose an internal cavity definedwithin the sterile barrier housing, the cavity configured to selectivelyreceive a motor pack therein.
 4. The robotic surgical system of claim 1,further comprising a motor pack supported in the sterile barrierhousing.
 5. The robotic surgical system of claim 4, wherein the motorpack rotates with the drive transfer assembly relative to the sterilebarrier housing.
 6. The robotic surgical system of claim 1, furthercomprising a tension pulley operably coupled to the drive belt.
 7. Arobotic surgical system comprising: a surgical instrument defining alongitudinal axis between proximal and distal ends thereof; aninstrument drive unit configured to transmit rotational forces to thesurgical instrument while the surgical instrument is coupled to theinstrument drive unit; and a carriage supporting the instrument driveunit and the surgical instrument while the surgical instrument iscoupled to the instrument drive unit, the carriage including: aninstrument rotation pulley; a motor axis pulley; a drive belt coupled tothe instrument rotation pulley and the motor axis pulley; a couplingengaged with the motor axis pulley such that rotation of the couplingrotates the drive belt around the instrument rotation pulley and themotor axis pulley to rotate the surgical instrument about thelongitudinal axis of the surgical instrument; and a robotic armsupporting a rail, the carriage being movably mounted to the rail of therobotic arm, wherein the carriage includes a rear panel coupled to therail and a coupling flange extending from the rear panel, the couplingflange rotatably supporting the instrument rotation pulley.
 8. Therobotic surgical system of claim 7, wherein the instrument drive unitincludes a sterile barrier housing having a drive transfer assemblyextending therefrom, the drive transfer assembly configured to couple tothe surgical instrument.
 9. The robotic surgical system of claim 8,wherein the sterile barrier housing includes a cap, the cap removable toexpose an internal cavity defined within the sterile barrier housing,the cavity configured to selectively receive a motor pack therein. 10.The robotic surgical system of claim 8, further comprising a sterilebarrier collar assembly configured to couple to the drive transferassembly, the sterile barrier collar assembly configured to support thesurgical instrument while the surgical instrument is coupled to thedrive transfer assembly.
 11. The robotic surgical system of claim 10,wherein the drive transfer assembly and the sterile barrier collarassembly rotate together in response to rotation of the instrumentrotation pulley so that the surgical instrument rotates while coupled tothe sterile barrier collar.
 12. The robotic surgical system of claim 8,further comprising a motor pack supported in the sterile barrierhousing, the motor pack configured to engage the drive transfer assemblyso that the drive transfer assembly provides a sterile interface betweenthe motor pack and the surgical instrument.
 13. The robotic surgicalsystem of claim 12, wherein the motor pack rotates with the drivetransfer assembly relative to the sterile barrier housing.
 14. Therobotic surgical system of claim 7, wherein the carriage furtherincludes a tension pulley operably coupled to the drive belt.
 15. Arobotic surgical system comprising: a carriage configured to be coupledto a robotic arm and rotatably supporting an instrument rotation pulleyand a motor axis pulley; a drive belt coupled to the instrument rotationpulley and the motor axis pulley; a motor supported by the carriage andincluding a coupling that is driven by the motor upon an actuation ofthe motor, the coupling engaged with the motor axis pulley such thatrotation of the motor axis pulley rotates the drive belt to rotate theinstrument rotation pulley; a sterile barrier housing including a drivetransfer assembly configured to couple to a surgical instrument; and amotor pack supported in the sterile barrier housing.
 16. The roboticsurgical system of claim 15, wherein the sterile barrier housingincludes a cap, the cap removable to expose an internal cavity definedwithin the sterile barrier housing, the cavity configured to selectivelyreceive the motor pack therein.
 17. The robotic surgical system of claim15, further comprising a sterile barrier collar assembly configured tocouple to the drive transfer assembly, the sterile barrier collarassembly configured to support the surgical instrument while thesurgical instrument is coupled to the drive transfer assembly.
 18. Therobotic surgical system of claim 17, wherein the drive transfer assemblyand the sterile barrier collar assembly rotate together in response torotation of the instrument rotation pulley so that the surgicalinstrument rotates along a longitudinal axis thereof while coupled tothe sterile barrier collar assembly.
 19. The robotic surgical system ofclaim 15, wherein the motor pack rotates with the drive transferassembly relative to the sterile barrier housing.
 20. The roboticsurgical system of claim 15, wherein the surgical instrument operablycouples to the instrument rotation pulley such that rotation of theinstrument rotation pulley rotates the surgical instrument.